BA - Super Pursuit - Engine Introduction

The Boss 290
Ford buffs know that this name was first used on a special engine fitted to the 1969 Mustang - the Boss 302. This revered engine shares many uncanny similarities with its modern-day heir. The Boss 290 delivers 290 kilowatts at 5,500 rpm, the same iconic power figure in kilowatts the original Boss 302 had in horsepower along with the first XW Falcon GT 351 on its 1969 release.
But the 520 Newton metre torque figure launches the new Boss 290 into a class all its own.

To fit the Boss 290 into the Pursuit without compromising ground clearance or stifling airflow, a special power bulge bonnet was factory-designed and tooled, creating a new level of authority on the street.


The Block: 

The block is cast-iron which makes it exceptionally rigid. It is three times stronger than aluminium for extra durability and refinement under high horsepower and torque loads. Cast-iron is more stable over a wider range of temperatures and there is less movement at critical sealing points for superior resistance to oil and coolant leaks. Ultimately, it's what we use for V8 Supercar engines.

The engine has an under-square bore and stroke ratio that delivers the flexibility, fast response and strong pulling power from low engine speeds expected from a high-performance V8.

A forged steel crankshaft maintains strength and refinement under high power and torque loads.

Each crankshaft undergoes a special balancing process at Ford Performance Vehicles prior to assembly to match the special Boss 290 piston and conrod combination for exceptional refinement and reduced stress on components at all engine speeds.

Locally-sourced high-performance tri-metal main and big-end bearings are specified for extra durability under higher engine speeds and peak power and torque loads.

Each main bearing cap is precisely located by two cross-bolts, two vertical bolts and two vertical locating dowels for superior location over six bolts. That means superior durability and refinement under high performance loads.

Each conrod is re-engineered to match the stronger pistons and floating gudgeons.

The conrod big-ends are separated by a controlled cracking process before main bearing insertion. When reconnected, this creates a multi-ridged join unique to each conrod that is exceptionally strong and virtually invisible.

Locally-supplied high-performance pistons with domed tops lift the compression ratio to 10.5:1 on 96 RON PULP for improved engine response, efficiency and fuel economy under light throttle loads.

The oil pump is driven directly off the crankshaft. So when the engine is running, the oil pump is too, therefore eliminating serious potential for engine wear.


Heads: 

Twin overhead camshafts per bank with four valves per cylinder to produce a deep-breathing, high-performance engine for exciting and consistent power and torque delivery right up to the red line.

The heads are cast in aluminium alloy to minimise weight and to reach the optimum operating temperature faster. They feature an improved Cobra R design with a straighter, better-breathing inlet port.

The camshafts are hollow for reduced weight, less inertia - and faster response.

Sealed, high-quality timing chains are lubricated by the engine's oil supply for long life. This means a major reduction in maintenance costs compared to timing belt replacement and eliminates the potential of engine damage through a missed belt change.

For critical engine joins, special high-tensile bolts are stretched under torque for maximum strength and extra resistance to loosening.


Intake: 

The inlet manifold is manufactured in Australia with tuned length trumpets to match the straighter inlet port of the latest head design for strong torque at lower engine speeds, accessible power at everyday speeds and deep breathing at high engine speeds.

A 75 mm throttle body with drive-by-wire linkage eliminates the noise and vibration path that a mechanical linkage generates as it enters the cabin.

The Boss cast-alloy plenum cover is made in Australia to meet the engine's specific deep breathing requirements without compromise. The Boss bonnet pressing was tooled to accommodate this design.

The Boss low-restriction air-intake system was developed and manufactured in Australia and incorporates the conical filter element from the Mustang Cobra. This optimises the air-flow to the inlet system.


Exhaust: 

The stainless-steel exhaust system was manufactured in Australia to reduce weight and generate a deep, resonant engine note.


Build Process: 

The new Boss 290 engine is meticulously assembled by hand at Ford Performance Vehicles on the only V8 production line in Australia, a $1.5 million investment that has already paid dividends.

By building their own engines, rather than importing a fully-assembled engine developed overseas, Ford Performance Vehicles retains ultimate control over the development of engines to answer the unique needs of Australian performance car enthusiasts.

To deliver the solid muscle at low engine speeds that Aussies expect in a high-performance V8 while maintaining the free-revving, deep-breathing feel of a thoroughbred sports engine, Ford Performance Vehicles has developed a unique engine that has no equivalent in the Ford world.

On this high-tech carousel, manned by technicians who previously honed their skills hand-building the previous Windsor V8s, each Boss 290 engine is carefully assembled from bare blocks and heads.

A pristine environment, the assembly line has more in common with a surgery than a factory. Indeed, to see the technicians huddled over an engine is truly reminiscent of an operating theatre. The latest computer-controlled dual-nut runners are used for the critical fastening and torquing of the heads, conrods and main-bearing caps. Far more sensitive than manual tightening, they are programmed to react instantly to faults in materials and parts, sending an instant alert to their operator.

As a result, the new line has enabled Ford performance Vehicles to adopt the latest world-class practices for our industry; not only in quality control but occupational health and safety too.

The end result is that the Boss 290 is one of the most powerful yet cost-effective V8 engines built anywhere in the world.  For comparable outputs from a similar V8 engine, you'd need to spend around $200,000 for a premium European brand.

         

To view details on the Factory BA Super Pursuit - click on the links below