To obtain this significant increase in performance, the inlet and exhaust systems have been re-designed and the camshaft timing revised.
Increased turbocharger boost pressure and a new, bigger intercooler also play a key role in delivering more power, more torque and improved performance feel.
The new larger intercooler reduces unnecessary losses in the intake and allows for a higher air intake pressure. Additionally, an improvement in heat rejection allows lower intake manifold air temperatures in all conditions.
“The intercooler remains in the existing position; it is chassis mounted in front of the radiator, however it has better airflow because we have removed the grill in front of it.” FPV’s Head of Powertrain Engineering Bernie Quinn said.
“We have re-tuned the wastegate to allow us to reliably achieve 310kW without any unwanted surges due to variation in boost pressure. The improvements made to the intake system, particularly the intercooler, have allowed us to maintain high levels of performance even in high ambient conditions.”
Engineers focused on volumetric thermal efficiency to ensure that losses were kept to an absolute minimum. A new “low loss” short path Air Intake System was developed to reduce losses and improve throttle response.
“With 100% of the peak torque available all the way from 1950 rpm to 5200 rpm, the new F6 310 engine transforms the performance feel of our F6 range, delivering seamless power and fantastic responsiveness across all driving conditions," Quinn said.
The Boss 315 engine has also been equipped with a new oil pan, which has been designed to suit the new front structure design in the FG Falcon, along with new exhaust manifolds to suit the new body structure.
Significant work was conducted to control and eliminate torsional vibration of the crankshaft, in order to achieve a higher rev range. This, combined with improvements to piston assembly strength and increases in engine volumetric efficiency, has allowed an increase of maximum revs from 6000 rpm to 6500 rpm.
FPV invested heavily in improving fuel efficiency and the Boss 315 provides a 4.8 percent improvement in fuel consumption with 14L/100km for the automatic transmission, down from 14.7L/100km in the BF MkII.
“It was always part of our brief to increase power and improve fuel efficiency, and by reducing losses and freeing the engine up we have increased the engine speed range. This means we’re able to get more air into the engine and that’s where we gain the extra power,” Quinn said.
FPV engineers conducted a substantial amount of durability testing, with a total of over 1800 hours of high speed load engine durability on the dyno, followed by thousands of kilometres of powertrain durability tests and a series of manifold shock testing.
“During our mechanical development, we created our designs then went chasing those designs and ideas with specific testing. We did a significant amount of development to optimise cam timing and valve lift, throttle body design and air cleaner filter selection,” Quinn said.
“We’ve broadened the torque curve so that it picks up better at a lower rev range and gives the driver easier access to torque, so you get that drive all across the rev range. By increasing the torque in the useable, mid-speed engine range we’ve also given the driver more flexibility in overtaking manoeuvres.”
A new six-speed manual transmission has been introduced with the FG FPV range, the new Tremec TR6060.
The Tremec TR6060 is now fitted to all manual transmission variants in the FG FPV range – replacing the T56 six-speed manual on previous F6 and GT sedan and ute models.
The new synchroniser package features triple synchromesh on first and second gears, and double synchromesh on all other gears, including reverse, which has significantly reduced gear shift efforts and shift travel.
The reduced shift travel provided by the synchroniser package has also allowed increased space for the use of larger gears, which are stronger to deliver improved torque capacity and gearbox durability.
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