5.0 Boss links of interest

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The New Boss V8

The wait is finally over! The new Boss V8 has arrived at FPV, bigger and better than ever. After months of testing and tens of thousands of kilometres travelled, the new Boss V8 is finally ready to be put through its paces when it goes on sale on Monday 25th October 2010.



Boss 5.0 litre V8

The previous 5.4 litre Boss V8 has done FPV proud and has been instrumental in the revival of the GT nameplate. However as it was unable to meet the strict Euro IV regulations that came into effect on 1st July 2010, a new engine needed to be sourced. Nicknamed "Coyote" the 5.0 litre all aluminium V8 was first seen in North America's Mustang GT in December 2009, however it has been substantially modified in FPV's V8 engine plant in Victoria for the Australian market.

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Supercharger

The new Boss V8 has a Harrop/Eaton designed HTV, 1900 front drive supercharger featuring:

* Eaton TVS 6th generation rotor set
* 1.9l per revolution displacement
* Torsional decoupler in supercharger drive shaft for optimised NVH
* PCM controlled inlet bypass valve
* Bypass operation for vacuum and boosted conditions

It contains a new cast aluminium high flow supercharger inlet duct and 75mm electronic throttle body.

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The 5.0 litre supercharged Boss V8 comes in 2 variants:


1. GT Engine

* 335 kW (DIN) @ 5750-6000 RPM
* 570 Nm (DIN) @ 2200 - 5500 RPM

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GT Engine performance graph

The iconic GT is now better than ever! The GT range consisting of the GT, GT-P and GT E are the ultimate V8 sedans, delivering greater low-down torque and superb power and handling.

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2. GS Engine


* 315 kW (DIN) @ 5750rpm
* 545 Nm (DIN) @ 2000 - 5500rpm

The GS nameplate will now take pride of place in FPV's model line-up. The GS is available in both sedan and ute variants and forms the base models in the FPV Euro IV V8 range.

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POWERTRAIN SYSTEM TECHNICAL SPECIFICATIONS



Air intake system


* New high flow cold air intake system
* New bonnet sealed open cold air box
* High flow conical filter

http://i162.photobucket.com/albums/t...55_resized.jpg

Exhaust system


* High flow thin foil technology metal matrix catalysts
* Twin brick catalyst construction
* 140mm diameter, 2.1litre per catalyst assembly
* New cold end exhaust with FPV unique NVH tune
* New quad outlet exhaust system
* Billet aluminium tail pipe finishers
* New mufflers with new FPV tuning code
* PCM controlled active exhaust system (Sedan only) to deliver:
o Refinement and comfort for part throttle cruising applications
o Maximum V8 sound quality at idle and car manoeuvring
o Maximum V8 muscle car sound quality during spirited driving

Fuel system


* New high flow fuel pump
* New two piece stainless steel fuel rail assembly
* 4 Bar pressure return system
* New high flow fuel injectors for:
o Increased flow range
o Optimised targeting for EU4 emissions

Vehicle Cooling System


* Brand new high efficiency radiator and fan pack assembly
* Twin variable speed fans
* New high efficiency automatic trans oil cooler system
* New engine oil cooler and cooling system
* Engine inlet thermostat control
* New vehicle heater circuit

Automatic Transmission


* Upgraded ZF 6HP26 transmission
* New 7 plate clutch pack and 4 planet planetary gearset for improved torque capacity

Manual Transmission


* Tremec TR6060 with new bell housing to suit new clutch system. Revise 2nd gear synchros for reduced shifting efforts

Clutch


* ZF twin plate clutch common with Mustang GT500. New clutch release bearing common with Mustang GT500.


fpv.com.au

Official release details.

http://theage.drive.com.au/motor-new...005-165bz.html

http://news.drive.com.au/drive/motor...005-165cd.html

http://www.goauto.com.au/mellor/mell...2577B300131D6F

What the media said when they got hold of them


Bathurst laps with J.C.
http://media.smh.com.au/drive/car-ne...t-1973509.html

http://news.drive.com.au/drive/motor...008-16am5.html

http://theage.drive.com.au/motor-new...005-165rc.html

http://www.caradvice.com.au/85953/fp...ote-v8-review/

Press articles in general

http://www.caradvice.com.au/82046/fp...for-gt-and-gs/

http://www.carsguide.com.au/site/new...te_v8_as_miami

http://news.drive.com.au/drive/motor...901-14n70.html

http://news.drive.com.au/drive/motor...901-14nbl.html-

http://news.drive.com.au/drive/motor...901-14n76.html

http://news.drive.com.au/drive/motor...901-14n8o.html


http://www.carsales.com.au/news/2010...arged-v8-21406

http://www.carsales.com.au/news/2010...arged-v8-21418

http://www.goauto.com.au/mellor/mell...257791001D3BB5

http://www.themotorreport.com.au/507...mi-v8-revealed

FPV LAUNCHES FIRST-EVER SUPERCHARGED GT RANGE

Wednesday, October 6, 2010

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Ford Performance Vehicles (FPV) today launched the first supercharged V8-engined GT in the 43-year history of Australia's most iconic performance nameplate.

FPV's high-tech, all-new, supercharged 5.0 litre V8 engine produces 335kW of power and 570Nm of torque, and is standard fitment across the GT, GT-P and GT E models.

It is the most powerful GT in the history of Ford's most famous Australian-made model.

To visually mark the arrival of FPV's new supercharged engine, the sporty new GT and GT-P feature distinctive new body graphics, including a 'hockey stick' stripe package and "Boss 335" identification, reminiscent of the famous 1970 Boss Mustang.

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The luxury GT E model retains its low-profile demeanour sans stripes.

"FPV is extremely proud of our new GT range, and very excited about what we have created," FPV General Manager Rod Barrett said.

"The new engine is amazing, its all-round performance frankly sets a benchmark for Australian-made cars, and the exciting thing is that it has been developed here, for our cars.

"FPV's customers certainly won't be disappointed by the performance of the new GT range, or in the way the cars drive, and they have real presence with the new graphics package.

"We've created cars that fully deserve to be part of the Falcon GT heritage and, I think, will write an exciting new chapter in the model's history."

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Developed locally by Prodrive in a $40 million program, the new FPV GT engine is based on the 'Coyote' Ford V8 first introduced in the American Ford Mustang earlier this year.

It's a sophisticated all-aluminium design with double overhead cams and 32 valves configuration, is individually hand-built for each car, fully EuroIV compliant and offers improved fuel efficiency.

The supercharged V8's compact size - 47kg lighter than the outgoing 5.4 litre Boss 315kW engine - offers packaging benefits which enhance the handling performance of FPV's new GT range.

"FPV's GT range now offers a whole new drive experience," Rod Barrett said.

"Thanks to the most modern engine ever offered in an FPV, all three GTs now provide tremendous, previously unheard of performance but do so in the smoothest, most responsive manner possible.

"They feature a brilliant engine, and thanks to a huge amount of work, make exactly the right noise too.

"At the same time, the GTs' handling has benefitted the lighter engine so turn-in response is sharper, and the whole car is more nicely balanced. The ride is also improved because we've be able to more finely tune the suspension front-to-back."

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A feature of the new GT, GT-P and GT E models is a quad-pipe bi-modal exhaust system which enhances both performance and the all-important exhaust note of the new cars.

Together with the new bodyside stripe, the GT and GT-P models get matching bonnet and rear wing graphics, and increased FPV identification via badging on the steering wheel, instrument cluster and key fob. There's also a new-design build badge.

This increased FPV branding is also featured on the GT E model.

Adding that final touch, all three GT models have new wheels as standard equipment.

The GT gets 19in five-spoke alloys with a machined face and Dark Argent accents, the GT-P gets 19in five-spoke alloys with a machined face and Sparkle Silver accents, and the GT E gets 19in 10-spoke alloys finished in Alpine Silver.

Available in 11 colour and three stripe combinations the GT and GT-P have the choice of three interior trim colours, while the GT E has eight exterior colours and two interior trim combinations.

fpv.com.au

Thursday, September 2, 2010

FPV ANNOUNCES SUPERCHARGED V8 ENGINE PROGRAM

Ford Performance Vehicles today announced a new range of supercharged V8 engines for its Australian-made performance car range.

To be launched in early October, the new FPV GS and GT model ranges will both be powered by all-new lightweight 5.0 litre supercharged Ford V8 engines producing 315kW and 335kW of power respectively.

Both engine configurations are more powerful, more fuel efficient and cleaner than any engines previously offered by FPV.

Developed locally by Prodrive in a $40 million program, the new FPV engines are based on the 'Coyote' Ford V8 first introduced in the American Ford Mustang at the beginning of this year.

"The new supercharged V8 engine program represents FPV's biggest-ever investment in the Australian market, and has been the most extensive and exhaustive development program we've ever undertaken," Prodrive Asia-Pacific Managing Director Bryan Mears said today.

"The outcome is phenomenal … these engines are brilliantly responsive, their performance is sensational, and they will take our next generation of FPV models to a level that's simply unmatched by anyone else."

FPV's first-ever supercharged engine, the new V8 is a sophisticated all-aluminium design with double overhead cams and 32 valves configuration, and is fully EuroIV compliant.

Its lightweight and compact size - the supercharged Coyote engine is 47kg lighter than the outgoing 5.4 litre Boss 315kW engine - also offers packaging benefits which enhance the handling performance of FPV's new GS and GT ranges.

The base of the new FPV V8 engine is imported from America in component form and each one is hand-assembled locally by FPV, utilising extensive Australian-made componentry.

"It's important to emphasise just how Australian these engines are," Bryan Mears said.

"Although the basis of the engine is imported, all the components utilised in the supercharged configuration are locally sourced, and the engines are completely hand-made by the team at FPV in Melbourne."

Heart of the Australian engine specification is a Harrop Engineering-developed supercharger utilising Eaton TVS technology.

Development program

FPV began its development of the new GS and GT engines in 2007, initially with a 5.4 litre XR8 'mule' engine fitted with a supercharger and custom manifolds. This was used for cooling system development and initial engine calibration strategy development before the first of three levels of prototypes were built around the 5.0 litre 'Coyote' Mustang engine.

Each of these prototypes advanced development of the engine, at first with hand-made componentry to trial various configurations, until a final specification was locked in, utilising pre-production parts and then final production components.

Engine power levels, torque curves and emission outputs were all refined throughout this process.

"One aspect of the program that was very important to us was the aural output of the engine … it is at the heart of the FPV brand that the engine sounds right as well as means business, so we put enormous effort into that," Bryan Mears confirmed.

"You're going to love the outcome!"

Finally, verification prototypes then embarked on an exhaustive 170,000 kilometre durability program around Australia, before the engineering program was signed off in July 2010.

Specifications

FPV will offer customers two engine specifications when the new GS and GT ranges go on sale in October.

The GS-spec engine produces 315kW of power at 5750 rpm and 545Nm of torque, from an incredible 2000 to 5500rpm!

Official fuel consumption and emissions figures* for the 315kW engine are as follows:

GS Manual Sedan - 13.6 l/100km, 324 g/km CO2
GS Auto Sedan - 13.7 l/100km, 325 g/km CO2
GS Manual - 14.0 l/100km, 333 g/km CO2
GS Auto Ute - 14.2l/100km, 335 g/km CO2

The GT-spec engine produces 335kW of power at 5750-6000 rpm and 570Nm of torque between 2200 & 5500rpm. Its official fuel consumption and emissions figures* are as follows:

GT/GTP Manual Sedan -13.6 l/100km, 324 g/km CO2
GT/GTP/GTE Auto Sedan -13.7 l/100km, 325 g/km CO2

* Combined cycle; tested to ADR81/02



For further details or to arrange interviews, please contact:

Dave Harding

Communications Manager
Ford Performance Vehicles
(03) 9226 6666
dave@mediacomservices.com.au


Link->http://www.fpv.com.au/news/detail/4

FPV ANNOUNCES GT BLACK LIMITED EDITION SERIES

Monday, August 8, 2011


FPV has today announced the launch of its most limited edition vehicle to date, the GT BLACK.

Responding to the overwhelming feedback received on the FPV Concept, revealed at this year's Australian International Motor Show, FPV have taken the popular black-on-black treatment and applied the stealth-looking paintwork to just 125 units of the current standard supercharged Boss 335kW GT, creating the FPV GT BLACK.

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"We were totally blown away by the positive feedback received from fans and show-goers on our Concept," FPV General Manager Rod Barrett said.

"We knew we had a winner with the black paintwork and we wanted to action something immediately. The public spoke and we listened and I am just thrilled we have been able to put the GT BLACK into production so quickly."

"All the feedback received has been collated and the results present exciting possibilities for the FPV brand in the future. The GT BLACK is the beginning of some exciting times ahead as we continue to work on new product and design enhancements to reflect the needs and wants of the market."

With all black finished styling, black alloy wheels, black tail pipes and all-new matt black striping decals the GT BLACK will display a striking presence on our roads.

"The FPV GT BLACK is available in one colour only, so there will be no confusion when it comes to placing an order for colour on this one"

The limited edition GT BLACK is powered by the much vaunted all-aluminium BOSS 335 5.0-litre supercharged engine with a maximum power output of 335kW at 5750rpm, combined with maximum torque of 570Nm delivered across a broad 2200-5500 rpm range.

The newest addition to the FPV stable will be finished in menacing Silhouette black paintwork and will carry the excellent features of the current GT range plus some exciting extras, including reverse camera and leather seating.

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An all-new styling matt black stripe decal will feature on the bonnet, rear wing and bodysides, with the black paint treatment also carrying over on to the front and rear bumpers and upper and lower grilles.

The fog lamp bezels have also been made black, as have the exhaust tips, while completing the exterior will be GT premium five-spoke 19-inch alloy wheels finished in gloss black with black wheel nuts.

Inside the all black theme continues with black leather trim throughout, a black finish around the Interior Command Centre (ICC) unit, tissue box and door spears, and a unique black gear shift badge on manual transmission models.

Further enhancing the collectability of the GT BLACK, each vehicle will come with its own unique build badge and certificate of authenticity.

"With only 125 units available, we urge interested buyers to act quickly, with a number of vehicles already pre-sold."

The recommended Manufacturer's List Price* for the GT BLACK is $74,290, at participating FPV Dealers only.

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*This is the manufacturer's list price for the vehicle only. A number of other components, including a dealer delivery fee, stamp duty, registration, compulsory third party (CTP) insurance and other statutory charges may be payable by a customer in relation to the purchase of this vehicle. As a manufacturer, FPV is not able to quantify the amount of these charges as they vary depending on a range of factors and individual circumstances, including the FPV Dealer the customer purchases the vehicle from, the State or Territory where that customer purchases the vehicle and the customer's age, driving record and other personal factors. The final transaction price for the vehicle will be as negotiated by the customer with their chosen FPV Dealer.

Tuesday, December 6, 2011
FPV ANNOUNCES UPGRADES TO EXISTING RANGE

Ford Performance Vehicles (FPV) has announced upgrades across its current range with the introduction of Ford’s new FG Falcon MkII.

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Featuring the very latest in smart technologies and combined with minor exterior design appointments, the revisions will boost the standard equipment levels of the FPV range, offering customers increased value.



“The Performance Car market in Australia is highly competitive and so naturally we are thrilled to be able to increase the standard specification offerings on all our vehicles,” FPV General Manager Rod Barrett said.

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Latest smart technologies



A new Interior Command Centre (ICC) with an advanced 8.0-inch colour touch screen headlines the list of smart technology features that will be standard on all FPV models.



While maintaining the overall appearance, form and functionality of the current ICC and Human Machine Interface (HMI) design, the addition of the new, larger and interactive ICC screen will give customers an advanced, yet user-friendly, interface to control all the main in-car functions such as audio, phone and satellite navigation systems.



On the luxury GT E, GT-P and F6 E models , the 8.0-inch colour touch screen will also feature a new integrated satellite navigation system with Traffic Message Channel (TMC)1 as standard equipment.

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The new touch screen navigation system includes the following features:

• “Green routing” – calculates the most economical route, as well as the fastest and shortest routes available

• Choice of 2D or 3D map modes

• Over-speed and speed camera warnings

• “Where Am I” feature to show nearby points of interest

• Street house numbers left and right displayed

• Advanced lane guidance and signpost information indicating which lane to use

• “Junction view” showing graphical representation of road

• Traffic Message Channel (TMC) 1

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The new touch screen interface replaces the remote control-based operation of previous-generation navigation systems, providing customers with a fully integrated and user-friendly driver assistance system.



The GS Sedan and GS Ute will now receive an alarm and the prestige audio system as standard – while all FPV models have been upgraded to include a new USB input facility to play MP3 audio files. In USB mode, the user can play and browse all MP3 files through the audio system.



Compatible USB devices include memory sticks, flash drives and external powered hard drives, while memory support is to a maximum of one terabyte. Once a USB device is connected, a pop up message will display "USB Connected" in conjunction with the flash indicator on the USB device, if one is fitted.

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Already standard equipment on the GT E and F6 E, the reverse camera will now form part of the package on the GT-P, GT, F6 and GS, while the reverse sensing system will bolster the extensive list of standard features on the GS sedan.



Using four ultrasonic sensors mounted in the rear bumper, the reverse sensing system assists the driver when reversing into or out of a parking space with an audible warning of obstacles at or near the rear of the vehicle. A graphic is also displayed on the Interior Command Centre (ICC) screen, to supplement the audible warnings.



Completing the interior upgrades to the FPV range will be the addition of FPV floor mats across all models.



Exterior Design Appointments



In the most significant exterior upgrade to the FPV range, the GS will be fitted with a new, more purposeful front fascia design with new sports front bumper featuring winglets and pronounced sculpting around the fog lamps and lower grille to create aerodynamic tunnels. The new front end also includes new upper and lower grilles with recessed black mesh, new signature projector headlamps with black bezels and unique fog lamp treatment with chrome/high silver paint finish.

Both the F6 Ute and GS Ute variants will now offer increased functionality for customers with the addition of a sports bar as standard equipment.



And a new lighting package complete with precision design projector headlamps will feature on all models in the FPV range, while premium five-spoke alloy wheels in Graphite will complete the design upgrade on the F6.



The revised FPV range will go on sale with the following recommended Manufacturer’s List Price* FPV GT $71,290, GT-P $82,540, GT E $82,990, F6 E $76,940, F6 $64,890, F6 Ute $55,990, GS $57,990 and GS Ute $52,990.



Six-speed automatic transmission is a no-cost option on the GT and GT-P, while the GT-E is available in auto only. Automatic transmission is also offered as a no-cost option on the GS & F6 range of vehicles.





1 Ford Australia has an agreement to provide the Suna Traffic Channel broadcast for a minimum of five years from the time of vehicle manufacture. Refer to www.sunatraffic.com.au for full details of coverage.

BASE ENGINE SYSTEM TECHNICAL SPECIFICATIONS

Bore: 92.2mm
Stroke: 92.7mm
Con-rod Length: 150.7mm
Compression ratio: 9.25:1

New Firing Order for reduced crankshaft and engine vibration
1, 5, 4, 8, 6, 3, 7, 2

Engine Block
Aluminium deep skirted block
6-bolt cross bolted mains
steel press in cylinder liners
piston squirting jets for low piston temps and increased durability

Cylinder Heads
high-flow 4 valve
DOHC
32V
roller finger followers
pent roof combustion chambers
55.98cc combustion chamber volumes

Valve Train
intake valves
o 2 x 37mm
o chrome plated steel material
exhaust valves
o 2 x 31mm
o high temp. chrome plated inconel material
12mm intake valve lift
11mm exhaust valve lift
chain-driven cam drive system
variable intake valve timing
fixed exhaust valve timing
common intake and exhaust valve springs, retainers, collets, seals

Crankshaft
forged steel crank
unique Miami engine balance specification

Crank shaft damper
twin-sheave pulley
supports
o 8pk supercharger drive system on rear sheave
o 6pk water pump and alternator drive on front sheave
unique frequency / damper tune

Con-rod
new high strength powder sintered forged con-rod to suit supercharged application



Piston, ring and pin
new generation light-weight high strength piston and ring pack
hard anodised top ring groove
floating pin design
nitrided steel piston pin

FEAD (Front end accessory drive)
2 drive systems
1 x 8pk belt which drives supercharger, power steering and AC compressor
1 x 6pk belt which drives water pump and alternator

Lubrication System
new cast aluminium high-volume winged oil pan
cast in baffles for oil control under heavy cornering, braking, acceleration
G-rotor style oil pump
full length composite windage tray
engine oil cooler

Ignition System
coil on plug
new iridium fine electrode tip spark plugs

Exhaust manifolds
new cast stainless steel high flow EU4 exhaust manifolds
optimised for cylinder flow balance and emissions performance

Supercharger inlet duct and eTB assy
new cast aluminium high-flow supercharger inlet duct
75mm electronic throttle body

Supercharger assembly
Harrop / Eaton designed HTV 1900 front drive, rear entry supercharger featuring:
o Eaton TVS 6th generation rotor set
o 1.9l per revolution displacement
o torsional decoupler in supercharger drive shaft for optimised NVH
o PCM controlled inlet bypass valve
o bypass operation for vacuum and boosted conditions

Intake manifold
new two-piece cast aluminium intake manifold
supercharger mounted under intake plenum as low as possible in engine vee providing:
o optimised weight distribution / lower centre of gravity
o optimised NVH
o optimised air path and runner tuning
o optimised engine performance
tuned length intake runners
features supercharger outlet air diffuser which
o controls air charge motion out of the supercharger
o delivers ideal cylinder to cylinder flow balance


POWERTRAIN SYSTEM TECHNICAL SPECIFICATIONS

Air intake system
new high-flow cold air intake system
new bonnet sealed open cold air box
high-flow conical filter

Exhaust system
high-flow thin foil technology metal matrix catalysts
twin-brick catalyst construction
140mm diameter, 2.1 litre per catalyst assembly
new cold end exhaust with FPV unique NVH tune
new quad outlet exhaust system
billet aluminium tail pipe finishers
new mufflers with new FPV tuning code
PCM controlled active exhaust system (Sedan only) to deliver
o Refinement and comfort for part throttle cruising applications
o Maximum V8 sound quality at idle and car manoeuvring
o Maximum V8 muscle car sound quality during spirited driving

Fuel system
new high-flow fuel pump
new two-piece stainless steel fuel rail assembly
4 Bar pressure return system
new high-flow fuel injectors
o increased flow range
o optimised targeting for EU4 emissions


Vehicle Cooling System
Brand new high-efficiency radiator and fan pack assembly
Twin variable speed fans
New high-efficiency automatic trans oil cooler system
New engine oil cooler and cooling system
Engine inlet thermostat control
New vehicle heater circuit

Automatic Transmission
Upgraded ZF 6HP26 transmission
new 7-plate clutch pack and 4-planet planetary gearset for improved torque capacity

Manual Transmission

Tremec TR6060 with new bell housing to suit new clutch system. Revised 2nd gear synchros for reduced shifting efforts

Clutch

ZF twin plate clutch common with Mustang GT500. New clutch release bearing common with Mustang GT500.



Engine Development Program:

Four levels of prototype:

Mule-level prototype – 5.4 litre XR8 engine fitted with supercharger and custom-fabricated manifolds. Used predominantly for cooling system development, calibration feasibility and performance and driveability target setting

A-level prototype – 5.0 litre Coyote Mustang prototype engines fitted with prototype manifolds, prototype pistons, prototype oil pan. Used predominantly for calibration development, emissions feasibility, vehicle testing.

B-level prototype - 5.0 litre Coyote Mustang prototype engines fitted with fully representative prototype manifolds, fully representative pistons, fully representative oil pan. Used predominantly for calibration finalisation and refinement, emissions testing and development, vehicle testing and attribute assessment.

Verification prototype – 5.0 litre Coyote Mustang Verification prototype engines fitted with off-tool unique Miami pistons, Air intake system, exhaust manifolds and lubrication system. Used predominantly for sign off certification and durability testing, and attribute sign off.

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The Prodrive-developed high-performance Miami V8


“It took three years and $36 million but we believe the result is a new benchmark for a high-performance V8.” That is how Bryan Mears, Managing Director of Prodrive’s Asia Pacific Division, describes the 5.0-L supercharged power unit of the latest Australian-built Ford Falcon GT.

Prodrive had the task of creating what Mears regards as “essentially a new engine” although using the block, crankshaft, and some ancillaries of Ford's Coyote V8, which powers the 300-kW (402-hp) North American Mustang. The result is the supercharged Miami, which he describes as an affordable, world-class engine, designed and built to rigorous Ford standards.

Though naturally aspirated, the Coyote had been design-protected for a supercharged variant, but there was a great deal more to creating the Miami than simply bolting on a supercharger.

As with all new engines, regardless of capacity and power, it had to have environmentally responsible credentials and be capable of meeting future global emissions standards.

“The old 5.4-L ‘Boss’ unit used by Ford Performance Vehicles (FPV) was a tough act to follow, but it had reached the limit of its emissions development and mechanical strength,” explains Mears.

The Prodrive-developed Miami is 47 kg (103.6 lb) lighter. It also returns more power—335 kW (449 hp) at 5750 rpm, compared to 315 kW (422 hp) at 6500 rpm for the Boss unit. And as is required for the brand, there is more torque at lower engine speeds, with a claimed 570 N·m (420 lb·ft) available from 2200-5500 rpm instead of a peak 550 N·m (406 lb·ft) at 4750 rpm.

Straight-line performance figures for the Australian-built Falcon GT include a claimed standing start quarter-mile time of less than 13 s with 0-100 km/h (0-62 mph) in less than five seconds.

Prodrive is a British company that already runs the Ford Performance Racing team in the Australian V8 Supercar Championship. Its Asia-Pacific Technical Center, which incorporates its powertrain engineering group and led the Miami project, is close to FPV’s Melbourne facility.

The Miami program brought plenty of challenges. For a start, the engine had to meet the "One Ford” global standards for engineering and durability, yet be affordable at relatively modest volumes. Despite the company’s global philosophy, some 40% of the engine is manufactured in Australia and all engines are hand-built at FPV on the only V8 assembly line in the country. For the Falcon GS and GT models, this means around 1500 engines per annum.

The engine also had to embody the headroom to meet future emissions and performance targets, said Prodrive Australia’s Head of Programs Paul Cook.

The naturally aspirated Boss V8 uses aggressive valve timing to reach the required power output while satisfying EU3 emissions standards. This approach was felt to be incompatible with the need to meet EU4 requirements with improved low-speed torque. After investigating several design options, it was concluded that the most easily implemented path would be a supercharged engine running modest levels of boost.

The Coyote’s cylinder block design already included six-bolt, cross-bolted main bearing caps to provide stable crank location under the high load conditions. Its crankshaft had the necessary reserves of strength, and the front accessory drive was capable of accepting the increased loads of a supercharger drive, explained Cook.

But the Miami is a very different engine to the Coyote, he stated. So different that he regards it as “essentially new.”

The Harrop-built supercharger is the result of intense design and optimization. It uses Eaton TVS (Twin Vortices Series) rotors, to a specification developed by Jaguar in the U.K. (Harrop is the Eaton distributor in Australia.) It is housed in a casing designed specifically for FPV.

Computer simulation techniques allowed Prodrive engineers to achieve required supercharger installation criteria, especially the drive ratio and intake runners. The simulations proved it possible to reach the targets without an intercooler—quite a challenge when Australian summer ambient air temperatures in some areas can reach 45°C.

A complete new intake system positions the supercharger between the cylinder banks, providing an integral high-efficiency plenum and runners. The exhaust system uses a stainless steel manifold and a close-coupled catalyst for each bank. The new, four-tailpipe exhaust system includes an active flap to achieve regulatory compliance with what is deemed an appropriate sound.

“We put a lot of time into ensuring that the car will deliver a sound that our customers will enjoy,” says Cook.

Lightweight, low-friction pistons provide a compression ratio of 9.25:1 to suit the increased charge density and temperature. Stronger connecting rods, powder forged with precision-fractured caps, carry the increased firing loads and support a rev limit of 6250 rpm. The piston skirts are cooled by oil spray jets added to the block and ride on fully floating, nitrided wrist pins. Inconel exhaust valves are fitted.

Supercharging simplified the creation of different power options. As well as the 335-kW (449-hp) specification for the Falcon GT, GT-E, and GT-P, all running at 0.4-bar maximum boost, there is a 315-kW version, peaking at 0.34-bar (5.8-psi) boost, for the Falcon GS. Cook explains that this leaves untapped potential for future upgrades using higher boost levels, possibly using an intercooler.

Parts retained from the Coyote unit have been optimized for the Miami. The work includes rebalancing the crankshaft to suit the new piston and rod weights. The fuel injectors were found capable of the required flow, having been rated originally to be compatible with ethanol fuel blends. They were reset to suit the combustion characteristics of a supercharged engine.

Prodrive ran the Miami program as a "turnkey" project within the framework of Ford’s recently introduced Global Product Development System (GPDS), described by the company as a comprehensive and rigorous approach distilled from the best practices of Ford, Volvo, and Mazda. This saw Prodrive Australia becoming the nerve center for complex communications and logistics, coordinating input from Dearborn, MI; Canada; Germany; and the U.K.

Development and validation processes included accelerated engine endurance tests, simulating 250,000-km (155,342-mi) use in 14 weeks, and a vehicle durability program of 170,000 km (105,633 mi). The program used three levels of hardware: handmade prototypes for early evaluation, preproduction samples for development, and production parts for final validation.

Eight preproduction vehicles were taken through typical Australian drive cycles, with ultralong distance drives including the Outback. One crew drove from Melbourne to Darwin, 3752 km (2331 mi) across the Outback.

Mears believes that Prodrive saved FPV about a year compared to typical GPDS timing. “Because we’re not part of a large company, our decision-making process can be quicker and less influenced by factors outside the project,” he explained.

A central facet of this was extensive use of simulation and computer analysis, using computational fluid dynamics (CFD), one-dimensional simulation, and finite-element and nonlinear thermal-stress analysis. By applying nonlinear analysis, the Miami’s cast stainless manifolds passed their cracking test at the first attempt.

“All over the world, vehicle manufacturers struggle to make niche model programs financially viable in the face of substantial engineering costs,” says Mears. “The customer expects the same or better quality and durability from a limited-volume car as a mainstream model, yet the development overhead incurred must be recovered from a much smaller production run.

"We have produced an affordable, world-class engine to rigorous Ford standards through simulation for ‘right-first-time’ design and by the intelligent use of key existing parts. And there’s even the potential to sell finished engines back into the USA."
Stuart Birch

http://www.sae.org/mags/AEI/9352

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