Looking to add more than 100...
Looking to add more than 100 hp to your 4.6L Two-Valve? Look no further than basic bolt-ons. The basis for this series of tests was a '97 4.6L Two-Valve motor. In stock trim, these early (non-PI) motors were rated at 215 hp and 285 lb-ft of torque.
With the recent introduction of the new 5.0L motor from Ford, it seems obvious that the Modular motor program is here to stay. Those diehard enthusiasts of the original 5.0L who are still waiting for Ford to come to its senses and bring back a modern version of the original pushrod motor need to come to grips with the reality that Elvis has indeed left the building. Though gone, the original 5.0L is not forgotten, and lives on in a great many buildups.
Another engine looking to follow in the footsteps is the original 4.6L Two-Valve motor. Not quite on par with the new or old 5.0L in terms of industry significance, there are (nonetheless) literally thousands of 4.6L Two-Valve motors around begging to be modified.
But do you stick with the all-motor, bolt-on route, step up to a stroker, or opt for forced induction? Heck, for that matter, why not combine a couple and toss in some nitrous for the ultimate in Two-Valve performance?
Fans of the all-motor route seek to optimize the flow, efficiency, and compatibility of their chosen components. Obviously, the forced-induction crowd relies on boost, while the nitrous contingent just adds a little squeeze. There are arguments for and against all three methods, as it takes one heck of an all-motor buildup to equal the power of a blower or turbo motor. That is where additional displacement via the stroker might come into play.
Naturally, we ditched the...
Naturally, we ditched the stock exhaust manifolds in favor of a set of Hooker long-tube headers. The 1 5/8-inch headers fed 18-inch pipes.
All testing was performed...
All testing was performed using the FAST XFI engine management system. Dialing in the air/fuel and timing curves was critical for maximum performance. Diablo, SCT, or other hand-held flash tuning systems can be used to tune the motor in the car.
We drained the old motor oil...
We drained the old motor oil and replaced it with fresh 5W-30 Lucas synthetic. We had plenty of dyno runs in store for this motor and wanted to make sure it lasted through all of our testing.
Since power output and cost are interrelated, building more NA power becomes quite expensive at some point given the output. Blowers and turbos offer impressive power potential, but problematic blower belts and turbo/intercooler fitment are issues that require attention. Plus, the well-designed turbo kits can drain your wallet. Of course, nitrous owners are labeled bottle-babies, but it's hard to argue wiht the power that is available at the push of a button. One thing for certain is that the debate will rage on as long as people have different opinions.
The reality is that there isn't one ideal avenue for performance. Even if we limit the desired power output to a nice round 400 hp, it doesn't take a genius to see that same 400 hp could be applied differently for different applications. Assuming the same peak power output, a heavy tow vehicle (especially a diesel) would require a decidedly different power curve than a hot street/strip Mustang. In addition to being application-specific, the power output can be component-specific as well, as there are many different combinations that can be assembled to reach the desired goal.
Plucked from a local wrecking yard, we began with a 197 Two-Valve, which means the early non-PI variety. Substantially weaker than the later 260hp PI version, the non-PI was the motor Ford offered to replace the original 5.0L. Unfortunately for Ford, the non-PI 4.6L lacked both torque and the high-rpm horsepower promised by the fancy overhead cam design.
Run in stock trim with the...
Run in stock trim with the Hooker headers and a simple air-intake system, the otherwise-stock '97 4.6L produced 266 hp at 5,000 rpm and 341 lb-ft of torque at 3,600 rpm. Judging by where non-PI engines make peak power, they were obviously tuned for torque.
We started our list of bolt-on...
We started our list of bolt-on modifications right at the top by removing the factory throttle body and inlet elbow. Accufab supplied this trick billet-aluminum, 75mm throttle body. The airflow offered by the AccuFab unit was more than sufficient to feed the needs of our naturally aspirated Two-Valve.
Our test mule was a high-mileage unit, but a compression test revealed it still had plenty of performance left. After upgrading to Lucas synthetic oil, the motor was installed on the engine dyno and equipped with a Meziere electric water pump, Hooker long-tube headers, and a FAST engine management system. Using the FAST management system, the '97 GT motor was tuned to provide 266 hp at 5,000 rpm and 341 lb-ft of torque at 3,600 rpm. These non-Power Improved motors weren't rev happy, but they did manage to produce acceptable low-speed torque. Torque production from the 4.6L motor exceeded 300 lb-ft from 2,500 rpm to 4,600 rpm.
You may be wondering why an otherwise-stock '97 GT motor rated at just 215 hp produced over 260 hp on the engine dyno. The answer is quite easy, as the Ford rating of 215 hp came with a complete induction system; a full exhaust, including cats; and full accessories. The rating also includes running at operating temperature and using the factory tune (for air/fuel and timing).