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ENGINE HISTORY 4.6L/5.4L V8 AND 5.8L “MODULAR” (CONTINUED) via late-intake valve closing, a fuel-economy An Eaton® Roots-style supercharger was added 5.4L SOHC 2V/3V technique later applied to Toyota and Ford for the 390 horsepower 2003-2004 SVT To replace the 5.8L OHV, a longer stroke version hybrid engines. The transverse-engine vehicle Mustang Cobra, code named “Terminator.” of the 4.6L was developed for 1996 F-150. The packaging created the legacy of this application: Because of the high cylinder pressures, Romeo’s 5.4L’s undersquare geometry creates challenges, 100 mm bore centers and tight bore offset used aluminum block was replaced with the 2V’s such as higher piston speeds and less stiff crank for all 4.6L/5.4L/6.8L engines cast iron block. geometry. To maintain good NVH and durability, The 1996 Mustang SVT Cobra increased 4V The new Terminator left a gap in the Mustang numerous changes were made to beef up the performance to 305 horsepower with cylinder line-up, going down to the 260 horsepower 4.6L original 4.6L, such as a forged steel heat-treated head intake-port revisions and a new side-entry 2V Mustang GT, so the original SVT Cobra engine crank with eight-bolt flange, stronger head intake manifold. Durability enhancements was revised for the 305 horsepower 2003-2004 casting material, and redesigned tight main included a fully counterweighted steel forged Mustang Mach1 feature car, including a working bearing cap alignment dowels. Longer stroke crankshaft for the higher engine speeds with a shaker hood scoop mounted to the engine and and connecting rods drove a higher block deck manual transmission, in addition to a crankcase available automatic transmission (with cast height. Select fit main bearings and floating windage tray, handling-baffled oil pan, and a crankshaft). 2003-2005 Lincoln Aviator and piston pins were adopted from the 4.6L 4V. A patented full-flow oil cooler. Power rating 2003-2004 Mercury Marauder also featured this high-strength cast iron crank was developed for increased to 320 horsepower in 1999, with base engine. Early 2003- and 2005-model 2V Econoline applications. “tumbleport” cylinder heads enabling deletion of production used the Nemak®-Monterrey® cast Cylinder head layout, port design, and camshaft the Intake Manifold Runner control. aluminum block; later 2003 and 2004 timing have been tied to the 4.6L development. Unfortunately, production variations resulted in production used the Windsor-made (Cosworth® The 1996 two-valve original swirl port was inconsistent peak-power performance, requiring process) aluminum castings. upgraded to the Performance Improved (PI) port customer exhaust system component retrofits Ford Racing’s 5.0L Cammer crate engine is based and camshaft in 1999 for F-150 and Expedition. and a production hiatus for 2000 model year. on a bored version of the 4.6L 4V. There are F-250/F-350 Super Duty and Econoline followed The Cobra was relaunched for 2001 model year, other ways to this iconic displacement: Some in 2000. with intake manifold improvements supporting 5.0L short blocks have been created with only 300 horsepower arrived in 2003, with the three- better robustness to the 315 horsepower rating. stroke increase, and others have combined bore valve cylinder head for Falcon (Australia) and The Cobra also migrated in-cycle from the and stroke increase. the redesigned 2004 model F-150, and came to Teksid®-cast to Windsor-cast aluminum block; Expedition and F-Series Super Duty applications function was unaffected. for 2005. The truck intakes used a Charge Motion Control Valve (CMCV) port throttle, similar to the original 4.6 4V IMRC, to shroud the two intake ports. This CMCV was deleted for 2009 5.4L models, with slight chamber changes restoring in-cylinder motion. The three-valve layout drives tight packaging of the centrally mounted spark plug, so a special long-reach plug design was developed; this plug design migrated to a smaller diameter (12 mm cylinder head thread) in early 2008. Originally branded “Triton” for F-Series, E-Series, and Expedition applications, the 5.4L is most associated with Windsor Engine Plant, but engine assembly and machining have also been supplemented by the Essex Engine Plant nearby. For performance applications, the 1999 F-150 SVT Lighting used a 360 horsepower 5.4L 2V with an Eaton® Roots-style supercharger, upgraded to 380 horsepower for 2001-2004 models, with a detuned version offered in the 2002 Harley-Davidson® edition F-150. The 2007- 2008 F-150 Harley-Davidson® edition was also offered with a retrofitted Roots-style supercharger. Of course, Ford Racing offers many performance parts for all of the 5.4Ls. 5.4L/5.8L DOHC 4V The combination of Romeo 4V cylinder heads and the Windsor 5.4L bottom end began with the limited production 2000 SVT Cobra R, hand- assembled at Ford’s Engine Manufacturing For important information about the proper usage of performance parts, please see page 14. 88 Techline (800) FORD788 See pages 286-292 for important safety, emissions and warranty information.


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