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Building a 405-HP Cobra Engine
This engine buildup shows the assembly of a 2001 4-valve Cobra engine. For this particular
buildup, we wanted to shoot for a broad and usable powerband that would be perfectly suited for a
daily-driven street car. To produce some solid, reliable power that wouldn’t cost us an arm and a
leg, we built this naturally-aspirated engine with forged rods and pistons, ported cylinder heads,
stage-1 camshafts, and a ported intake manifold.

After going through the proper break-in techniques, we performed a leak-down test to verify that
the rings were properly seated and the valves were sealing correctly. We decided to use 91-octane
fuel, a stock computer, 1 3/4-inch long-tube headers, and a 3-inch X-pipe to help simulate a real-
world, in-car setup. We were more than happy to find that our engine peaked at 405 horsepower
and 382 ft-lbs of torque and managed to produce the power in a very usable RPM range. Check
out the following pictures and the dyno chart to get the complete story.
Oil gallery plug installation on a 4.6 engine block Installation of main cap studs on a 4.6L engine block
This is the installation of the front and
rear oil-gallery plugs.
Install the main studs in the block. Just
tighten the studs until they are snug.
Upper bearing shell installation Crankshaft thrust washer intallation on a 4.6 engine block
Install upper bearing shells and
lubricate bearing surface with SAE 30
oil.
With the crankshaft placed in the
crankcase, the crankshaft thrust
washer may be rotated into position
between the engine case and the
crankshaft thrust surface.
Setting the main caps of a 4.6 Liter Engine Torquing the main caps during engine assembly
After applying liberal amounts of SAE
30 oil to the crankshaft bearing
surface, the main bearing caps may be
set in place with a hammer.
Torque main bearing caps in the
correct sequence.
Installing and torquing the main cap side bolts on a 4.6 engine Checking crankshaft end play during engine assembly
Install and torque the side bolts in
sequence. And don’t forget to check to
make sure the crankshaft rotates
smoothly after you’ve finished torquing
everything down.
Crank end thrust clearance may be
checked with a dial indicator. The
clearance will be set at .008 of an inch.
Measuring the connecting rod bolt stretch to determine proper torque
Rod-bolt stretch is measured
with a dial indicator to
determine the torque required
to achieve the desired stretch.
The free length of each rod
bolt is also recorded on the
build sheet for future
reference.
Previous


This has been a sample page from

How to Build Max Performance 4.6 Liter Ford Engines How To Build Max Performance 4.6 Liter
Ford Engines
by Sean Hyland
This revised edition features new and current
information throughout the text, an additional 16 pages,
and all black and white photography.
When the ’96 Mustang came out with the 4.6-liter V-8, some
performance enthusiasts were scared away by its technology. But
those days are long gone. Ford added horsepower and torque to
its 2- and 4-valve V-8s over the years, and the number and
quality of available aftermarket performance parts has exploded.
Ford took things to the next level with the new 3-valve Mustang
GT engine and the 5.4-liter GT and Shelby GT500, adding even
more high-performance options.

In this updated edition of How To Build Max-Performance 4.6-Liter
Ford Engines, Sean Hyland gives you a comprehensive guide to
building and modifying Ford’s 2-, 3-, and 4-valve 4.6- and 5.4-liter
engines. You will learn everything from block selection and
crankshaft prep, to cylinder head and intake manifold
modifications. He also outlines eight recommended power
packages and provides you with a step-by-step buildup of a
naturally aspirated 405-horsepower Cobra engine. This is the
definitive guide to getting the most from your 4.6- and 5.4-liter
Ford.

4 Left in Stock, Order Soon! More on their way!

Click below to view sample
pages from each chapter.
Chap. 1 - Engine Block
Chap. 2 - Crankshafts
Chap. 3 - Rods
Chap. 4 - 4.6 Pistons
Chap. 5 - Cylinder Heads
Chap. 6 - Int. Manifolds
Chap. 7 - Fuel Injection
Chap. 8 - 4.6 Camshafts
Chap. 9 - 4.6 Exhaust
Chap. 10 - Ignition
Chap. 11 - Lubrication
Chap. 12 - Cooling
Chap. 13 - Power Adders
Chap. 14 - Packages
Chap. 15 - 405HP Engine
Softbound
8-1/2 x 11
1
44 pages
445 B/W Photos
Item #SA82P
Price: $22.95
Click here to buy now!
This is a great book that any modular engine owner or enthusiast will enjoy!

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