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Prodrive turns the Falcon into a real Boss – Click above to view high-res image gallery

The latest news from Oz comes courtesy of Prodrive, which has a close relationship with Ford Performance Vehicles. Starting with a Coyote V8 engine block, Prodrive has created a supercharged V8 that's lighter and more powerful than the naturally-aspirated unit it started with.

Known as the "Miami" engine, the supercharged V8 generates 449 horsepower at 5,750 rpm and 420 pound-feet of torque from 2,200 rpm up to 5,500 rpm. By altering the boost levels, Prodrive offers a less powerful version that produces 422 horsepower.

Both versions are planned for use in various trim levels of the Ford Falcon four-door. The 315kw (422 hp) unit will be available in the Falcon GS while the 335 kW (449 hp) engine is offered with the Falcon GT, GT-E and GT-P. The Falcons will wear the Boss name on the fenders and both versions provide yet another reason to book a flight on Qantas.

Ford Falcon Boss 335
  • Ford Falcon Boss 335
  • Ford Falcon Boss 335

  • Prodrive supercharger Ford V8
  • Ford Performance Vehicles (FPV) Project Coyote Engine.FPV plant.Campbellfield, Victoria.3rd of August 2010.(C) Joel Strickland Photographics.Use information: This image is intended for Editorial use only (e.g. news or commentary, print or electronic). Any commercial or promotional use requires additional clearance.

  • Prodrive supercharger Ford V8
  • .(C) Joel Strickland Photographics.Use information: This image is intended for Editorial use only (e.g. news or commentary, print or electronic). Any commercial or promotional use requires additional clearance.

  • Prodrive supercharger Ford V8

[Source: Prodrive]
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AUS$36million development programme delivered to Ford's demanding global standards

A new supercharged 5.0-litre V8 engine has taken the latest Ford Falcon GT models straight into the lead in the Australian performance car market. Developing 335kW at 5750rpm and 570Nm all the way from 2200 to 5500rpm, the Prodrive-designed 'Miami' engine has been universally applauded by the region's specialist press.

"The old 5.4-litre '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 Bryan Mears, Managing Director of Prodrive's Asia Pacific division. "It took three years and AUS$36million but the result is a new benchmark for a high-performance V-8."

In an example of performance-engine downsizing, the Miami replaces a naturally-aspirated 5.4-litre V8, saving 47kg yet providing more power. The supercharger also helps it to deliver more torque at lower engine speeds than its predecessor, ensuring the effortless acceleration typical of the FPV brand. Straight line performance figures include a standing start quarter-mile time of less than 13 seconds and 0-100kmh (62mph) in under five seconds.

The new engine even contributes to improved handling. Being lighter, it allows a more neutral front/rear weight bias.

The Miami engine is produced in two power ratings by altering the level of boost from the supercharger: a 315kW model in the Falcon GS and a 335kW version in the Falcon GT, GT-E and GT-P. These four high-performance vehicles are produced for the Australian market by Ford Performance Vehicles (FPV), a joint venture between Ford and Prodrive, and are the latest in a series of high performance versions of regular Ford models built by the company.

Global programme

FPV commissioned Prodrive's global powertrain engineering team, headquartered at its Asia-Pacific technical centre in Melbourne, to develop the new engine. "The challenge for the project team was to find an affordable way to produce a new, market-leading engine with the headroom to meet future emissions and performance targets," says Mears. "It also had to satisfy the demanding new 'One Ford' global standards for engineering and durability."

Within the Ford empire, the team identified the Coyote V-8 block and twin overhead cam cylinder heads from the 300kW USA Mustang as an ideal starting point. Using simulation techniques, Prodrive established the boost levels necessary to deliver the required power characteristics. By optimising the supercharger installation, especially the drive ratio and intake runners, it was possible to reach the targets without an intercooler. This leaves untapped potential for future upgrades using higher boost levels with an intercooler, should these be required.

New parts include uprated exhaust valves, pistons, connecting rods, the complete intake and exhaust system, a high-capacity sump and oil cooling jets to control piston temperature. Even parts that are retained from the Mustang have been optimised for the new application, such as resetting the standard fuel injectors to suit the new combustion characteristics and rebalancing the crankshaft to suit the new pistons and rods. Unlike a 'bolt-on' supercharger conversion, engineering changes are carried right through the engine to ensure long term reliability.

Prodrive ran the Miami programme as a 'turnkey' project within the framework of Ford's recently introduced Global Product Development System (GPDS). Prodrive Australia became the nerve centre for complex communications and logistics, coordinating input from Dearborn (USA), Canada, Germany and the UK. Powertrain and vehicle testing locations included Germany, the USA and Australia's Northern Territories.

Rigorous development and validation processes included accelerated engine endurance tests, simulating 250,000km use in 14 weeks, and a vehicle durability programme of 170,000km. The programme used three levels of hardware: hand-made prototypes for early evaluation, pre-production samples for development and production parts for final validation.

Approximately 40 percent of the engine is manufactured locally and all engines are hand-built at FPV on the only V-8 assembly line in Australia. For the Falcon GS and GT models, volume is predicted to be around 1500 engines per annum.

"All over the world, vehicle manufacturers struggle to make niche model programmes 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. The Miami project has been so successful that there's even the potential to sell finished engines back into the USA. That would be quite a compliment."

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    • 1 Second Ago
      • 4 Years Ago
      dear ford,

      the fusion sucks. bring this over immediately thanks.
        • 4 Years Ago
        The fusion doesn't really suck as v6 kid hauler. But to the austrailian and euro counterparts the fusion sport sucks ass. It's not fair that ford was born here and we get this fwd, 260hp, 4000 crap.
        • 4 Years Ago
        Instead of saying that it suck, why don't you actually explain why it sucks? Because from the reviews I've read on the Fusion and the many a friends I know that own one, there's barely any complaints about the car.
      • 4 Years Ago
      Its funny how autoblog are getting the news only now when the car has been out for over three months.
      • 4 Years Ago
      The American Taurus is an overweight slighty updated ratty old volvo platform, it has no manual transmission and is similar in lenth to a Tahoe. Let's see ford use it's "One Ford" policy and bring a falcon, with the manual to the Americas and call it a Taurus!
      • 4 Years Ago
      lol, teh Mustang and falcon merrging platforms is suicide for the Falcon. Mustang has useless engine, crappy fuel efficiency, does not carry your family and has hORENDUS suspension... live AXLE?? lol, wtH??
        • 4 Years Ago
        Oh look, a troll.

        -Nobody else complains about the Mustang's live axle anymore because the intelligent people have realized how good it really is.

        -The new Falcon is already powered by the same engine found in the Mustang GT. So that part of your argument is moot.

        -How the hell is 26mpg "crappy"?

        Jesus, did you even research?
        • 4 Years Ago
        It more likely means that like the current Camaro, the next Mustang will be made out of the Ford Falcon, meaning it will gain IRS and rigidity. Hopefully.
      • 4 Years Ago
      Wish we had this in the States.
      • 2 Years Ago
      I guess Mad Max was good for something.It's good to know Ford enginuity still goes fast.Send some of to the U.S.border patrol.
      • 4 Years Ago
      My god what a hideous car. Keep it in the bush where nobody can see it. The boy racer paint is simply awful.
      • 4 Years Ago
      The supercharger is designed to greatly improve the torque curve, maximum torque comes on from 2200rpm. The Falcon is designed as both a sports car and a family car, you could have 4 passengers and a boot (trunk) full of luggage, not to mention with a 2 tonne trailer, and have fun up steep hills - something the torque curve of the naturally aspirated car wouldn't like so much...
      • 4 Years Ago
      It looks like the supercharger mounts below the air cleaner, outlet is pointed up, with long intake runners coming back down along the outside?

      Very cool setup. Can't think of a similar arrangement anywhere else. Makes it easy to add an intercooler later as well - aftermarket will supply it quickly, factory later.

      Gotta love the over the top approach from OZ.
        • 4 Years Ago
        That is how GM does it on the LS9. That "air cleaner" you mentioned is the intercooler. It lets you get the total package much lower in the vehicle than the traditional way of putting the blower ontop of the intercooler. Turbo or supercharging w/o an intercooler is beyond stupid and I wouldn't expect any reputable company to make a package without it.
        • 4 Years Ago
        The Prodrive website says that there is no intercooler at this point. Surprised me, too. Maybe the long aluminum runners help to shed a few degrees, but wedged into the V of the block, I can't see it being very efficient if that's the plan.
        • 4 Years Ago
        That is almost what a coyote puts out NA. Seems like a lot of trouble to go thru to get 10-3- hp and 30 lb/ft. Without an intercooler, the blower is not very efficient.
        • 4 Years Ago
        Autoblog this was news about 6 months ago.

        Yes this is about the same as the max figures for the Coyote, but with this torque kicks in a *lot* earlier and is more "drivable".

        Also, I've heard this setup has been engineered to go way past 400kW so it will be incremental updates... as soon as Holden tries to trump it they will turn it up a little to always have bragging rights. And yes, aftermarket will have lots of fun with this
      • 4 Years Ago
      Ford needs to bring the Falcon to the states!
        • 4 Years Ago
        Hate to say it, but recently I've heard (at least rumours) Ford Australia were talking about discontinuing the Falcon and replaces it with the Taurus
        • 4 Years Ago
        The grass is always greener... I would love to get the current SHO Ford Taurus over here because that thing looks good inside and out. As a matter of fact the interior of the Taurus walks all over that of the Falcon.
        • 4 Years Ago
        I hear you. I could definitely see myself driving a rear drive V8 sedan if I can have a manual gearbox. I can't afford a CTS-V though.
      • 4 Years Ago
      "Elmo Wrote:

      Trishield, you have once again shown your lack of knowledge.

      EcoBoost is used in Australia. They do sell the new Fiesta there and will be selling the new Focus there. Also, I believe the new Territory will be powered by the 3.5L EcoBoost and 2.0L EcoBoost.

      Oh and the I6 used in the Falcon...

      That was developed by Nissan."

      Sorry to rain on your parade Elmo, but you're completely incorrect. I'm from down under and I do know a fair bit about Ford Australia.

      * EcoBoost is not in Australia yet, the Fiesta does have a Econetic version but that's totally different to Ecoboost.
      * The Territory will not be powered by either the 3.5L or 2.0L EcoBoost, but rather the current 4.0L Inline six found in the Falcon and a 2.7L V6 diesel coming in a few months.
      * Nissan had nothing to do with the development of the Inline 6 - it's been in the Falcon since the 1960's. I think you're mixed up with Holden using Nissan's Inline 6 for while.
      * The only EcoBoost engine that will appear in the Falcon this year will be the 2.0L.

      The GT's power figures have shown to be underrated by dyno testing so far, the 335Kw figure is very close to what they're actually getting from the rear wheels.
        • 4 Years Ago
        Part of the reason I think FPV went with a blower was to get just enough power to win the paper war over HSV at this time. If HSV adopts more powerful engines than FPV can add an intercooler, retune and up their boost to beat them again. I would be interested in hearing FPV's rationale for the blower in an interview which I'm sure will happen sometime in the future.
      • 4 Years Ago
      That engine puts out healthy power and is very interestingly and intelligently
      designed! I wouldn't worry too much about the disparity in output ratings between
      supercharged and naturally aspirated versions-stock is usually just a starting
      point for many. Body's just okay but something in a plain wrapper WITHOUT those
      infantile 'graphics' would suit me better. Unfortunately we'll never have access
      to this here in the US:(
        • 4 Years Ago
        yeah, that coyote is pretty bad-ass. 6 (!) bolt mains with in block air control passages and cylinder liners that will be good for at least 500,000 miles of absolute abuse. everything is compact and lightweight and that 'free' variable cam timing seems like a mechanical miracle.

        the modular v8 has come a long way very quickly.
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