Key to the new engine's increased power, refinement and fuel economy, is a 3-valve cylinder head produced by Windsor Engine Plant and shipped to an all-new production line at Essex Engine Plant for final assembly.

The two-plant collaboration is Ford of Canada's most ambitious engine plant expansion in recent history, representing 70,200 m2 (780,000 ft2) of new facilities and an injection of millions in the economy of Canada's automotive heartland.

"Ford F-Series has been Canada's best-selling full-size pickup for 36 years and is one of our top nameplates in the world," said Alain Batty, Ford of Canada's president & CEO. "That underscores the importance of our new engine and Windsor's unique role in the success of the F-150."

"Windsor is the largest centre of engine production in Ford's global operations," said Chris Bolen, Plant Manager at Ford's Windsor Engine Plant. Bolen noted both Windsor and Essex Engine Plants are on track to surpass last year's production of 1.1 million engines.

Graham Harris, Ford of Canada's launch manager for the new engine, noted the new cylinder-head line at Windsor Engine Plant utilizes flexible manufacturing techniques.

"The installation of flexible manufacturing at Windsor Engine Plant is the first in what will be a global rollout of new and innovative manufacturing techniques at Ford engine facilities throughout the world," he said.

Construction to expand both plants began in Spring 2000. Essex Engine Plant has received a 22,500 m2 (250,000 ft2) building expansion that includes a new production line for the final assembly of the new 3-valve 5.4-litre TritonTM V-8 engines, as well as a new crankshaft machining area.

Although full production occurs in 2003, plant manager Aaron McKey has confirmed that limited assembly of a three-valve V-8 engine for the Ford Falcon range in Australia is already under way.

"Canadian-built engines are powering the impressive new Ford Falcon a world away in Australia. By next year, our engines will also be powering the next generation of the best- selling Ford F-150 pickup. These are significant pride points for the 2,000 men and women employed at Essex Engine Plant," said McKey.

The new TritonTM engine represents the first V-8 power plant produced at Essex Engine Plant. It will be added to Essex' current production of the split-port 3.8-litre V-6 engine for the Ford Windstar and Mustang, and the split-port, 4.2-litre V-6 engine for the F-150 pickup.