Bullshit. The CAFE thing is nothing more than a conspiricy theory. I could believe that Ford tightened up machining tolerances to make a more efficient motor which in turn would provide better mpg.
Edit: I've never noticed a difference in mpg vs 5w20 or 5w30 or 0w30. If better mpg was obtained with 5w20 why would that be? Better lubrication which results in less drag and resistance.
Here is why 5w20 is speced for the motor: Clearances. Minimum clearances for a 4.6 3v motor: Main bearing .0009", rod bearing .0009", side rod .006" cams to journal .001", piston to bore .0007". Pin to rod and piston .0004". Those are cold clearances. Does anyone know what the hot clearances are or how much change happens at operating temp? It's going to take a fairly thin oil to maintain a wedge and flow enough to take heat away. Even the 3v oil pump has it's own pressure relief value based on the speced oil.
You do remember that the oil recomendation was lowered halfway thru the production of the engines and ford even "ordered" thedealers to start filling the already built cars with 5w-20. What sudden change in clearances happened?
Do you have any documentation, research or else to prove the point?
You know whats the diference in weights right? Viscosity?
Scott Witthead which was of the main engineers on the 3v proyect has specifically said that he would not put 5w-20 on a 3v engine EVER.
Now please read the first paragraph of the TSB on the oil recomendation change.
TSB 01-4-7
ISSUE:
Engine oil recommended for use in 2001 vehicles is SAE 5W-20 motor oil. This
oil has an improved formulation to improve fuel economy. This oil can also
be used to service some previous model year vehicles.
ACTION:
Use SAE 5W-20 engine oil at recommended oil change intervals for 2001
vehicles, with the exception of the following vehicles listed in the
"Exception 2001 Vehicles" chart. All 2001 vehicles other than those listed
in the "Exception 2001 Vehicles" chart are being filled with SAE 5W-20 motor
oil at the factory and should also be serviced with SAE 5W-20 oil.
Viscosity is a measure of the resistance of a fluid which is being deformed by either shear or tensile stress. It is like the fluid friction, fill up a bucket with water and one with honey. Which one will take more force to circle a broom stick in it?
5W-20 oil is a lighter viscosity than a 5W-30 oil and therefore has less internal engine frictional losses, or less drag on the crankshaft, pistons and valvetrain, which in turn promotes increased fuel economy. This increased fuel economy is virtually undetectable to the average motorist without the use of specialized engine monitoring and testing equipment under strictly controlled test track driving when compared to a 5W-30, 10W-30 or a 0W-30 viscosity motor oil.
http://www.synthetic-oil-tech.com/d.cgi/1245917/ford5w20.htm
http://www.machinerylubrication.com/Read/518/motor-oils