Ford Modular Engine: What is it?

AaRoN

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Some info in case you didn't know ;D

The Modular engine is Ford Motor Company's modern overhead camshaft (OHC) V8 and V10 engine family. It gradually replaced the Windsor small-block and 385 big-block engines over several years in the mid-1990s. Contrary to popular belief, the Modular engine did not get its name from its design or sharing of certain parts among the engine family. Instead, the name was derived from a manufacturing plant protocol, "Modular", where the plant and its tooling could be changed out in a matter of hours to manufacture different versions of the engine family. [1]. It is used in Ford trucks, (called Triton) in Lincolns (called Intech) and in Ford and Mercury cars.
The engines were first produced in Romeo, Michigan :dancing6: but additional capacity was added in Windsor, Ontario.

4.6L
The first production Modular engine in the family was the 4.6 L (4601 cc, 281 in³) 2-valve SOHC V8 introduced in the 1991 Lincoln Town Car.

Over the years, the 4.6 has been offered in 2-valve SOHC, 3-valve SOHC, and 4-valve DOHC versions. It has also been produced with both iron and aluminum blocks. Bore and stroke are nearly square at 90.2 mm (3.552 in) and 90 mm (3.543 in) respectively. Deck heights for all 4.6 blocks are 227 mm (8.937 in). Connecting rod length is 150.7 mm (5.933 in) center to center. This gives the 4.6 L a 1.67:1 rod to stroke ratio.

Until 1999, all car engines were produced at the Romeo plant. In 1999 and 2000, Mustang engines were produced in Windsor. Production was moved back to Romeo in 2001 (thus the reason why the "mid" 2001 motor is alittle different). Most truck engines are from the Windsor plant, however there are many later model trucks with Romeo engines. All aluminum-blocked engines were produced at Romeo. In keeping with traditional Ford practice, as engine design is revised over time compatibility with previous versions is considered low priority, so that parts from a modular engine made in one model year are not necessarily likely to fit an engine made in another; and parts from an engine manufactured in Romeo are unlikely to fit an engine made in Windsor. The Romeo and Windsor plants have different designs for main bearings, heads (cam caps), camshaft gears (press-on vs. bolt on), valve covers (number of bolts), crankshaft (number of flywheel bolts), and cross bolt fasteners for main bearing caps.

The Modular DOHC was on the Ward's 10 Best Engines list for 1996, while the SOHC was on the list for 2005 and again for 2006.


2-valve

Modular 4.6L 2-valve SOHC V8 in a 2002 Ford Mustang GTVehicles equipped with the cast iron 16-valve SOHC 4.6 include the following:

1991-1993 Lincoln Town Car, 190 hp (142 kW)
1992-1997 Ford Crown Victoria/Mercury Grand Marquis, 190 to 210 hp (142 kW), 260 ft•lbf
1998-2000 Ford Crown Victoria/Mercury Grand Marquis, 200 to 215 hp (149 kW), 265 to 275 ft•lbf
2001-2002 Ford Crown Victoria/Mercury Grand Marquis, 220 to 235 hp (164 kW), 275 ft•lbf
2003-2004 Ford Crown Victoria/Mercury Grand Marquis, 224 to 239 hp (178 kW), 282 ft•lbf
2004-present Ford Crown Victoria Police Interceptor, 250 hp (186 kW), 287 ft•lbf
1994-1997 Lincoln Town Car, 210 hp (157 kW)
1994-1997 Ford Thunderbird, 205 hp (153 kW)
1994-1997 Mercury Cougar, 205 hp (153 kW)
1998-2000 Lincoln Town Car, 205 hp (153 kW)
2001-2002 Lincoln Town Car, 235 hp (175 kW)
2003-2004 Lincoln Town Car, 239 hp (178 kW)
2002-2005 Ford Explorer, 239 hp (178 kW) and 282 ft•lbf (382 N•m)
1996-1997 Ford Mustang, 215 hp and 285 ft•lbf
1998 Ford Mustang, 225 hp and 290 ft•lbf
1999-2004 Ford Mustang, 260 hp (194 kW) and 302 ft•lbf (410 N•m)
1997-present Ford F150, 248 hp (185 kW) and 294 ft·lbf (399 N·m) (ratings for 2007 and later model years)


3 valve
The 3-valve SOHC 4.6 L with variable camshaft timing (VCT) first appeared in the redesigned 2005 Ford Mustang.

The engines are equipped with an electronic Charge Motion Control Valve (CMCV) system that regulates the flow of air into the intake ports. Block material varies between the aluminum block used in the 2005+ Ford Mustang and 2006+ Ford Explorer and the iron block used in the 2004+ Ford F-Series, though aluminum heads are used in all applications.

The 3-valve SOHC engine was on the Ward's 10 Best Engines list for 2005 through 2007.

Vehicles equipped with the 4.6L 24-valve SOHC include the following:

2005+ Ford Mustang, 4.6 L, 300 hp (224 kW) and 320 ft•lbf (434 N•m)
2006+ Ford Explorer, 4.6 L, 292 hp (218 kW) and 300 ft•lbf (407 N•m)


4-valve
The 4-valve DOHC version of the Modular engine was introduced in the 1993 Lincoln Mark VIII. The 1999 and earlier engines featured an aluminum block cast in Italy by Fiat subsidiary Teksid S.p.A. The engine was revised for 1999 with new cylinder heads featuring tumble-style intake ports, new camshaft profiles, and an improved, fixed runner length intake manifold. These changes resulted in more horsepower, torque and a broader powerband.


Modular 4.6L 4-valve DOHC S/C V8 in a 2003 Ford Mustang SVT CobraVehicles equipped with the all aluminum 32-valve DOHC 4.6 include the following:

1993-1998 Lincoln Mark VIII, 280 hp (209 kW) and 285 ft•lbf (386 N•m)
1995-1997 Lincoln Continental, 260 hp (194 kW) and 265 ft·lbf (359 N·m)
1996-1998 Ford Mustang SVT Cobra, 305 hp (227 kW) and 300 ft•lbf (407 N•m)
1997-1998 Lincoln Mark VIII LSC, 290 hp (216 kW)and 290 ft·lbf (393 N·m)
1998-2002 Lincoln Continental, 275 hp (205 kW) and 275 ft·lbf (373 N·m)
1999/2001 Ford Mustang SVT Cobra, 320 hp (239 kW) and 317 ft•lbf (430 N•m)
2003-2004 Mercury Marauder, 302 hp (225 kW) and 318 ft•lbf (431 N•m)
2003 Ford Mustang Mach 1, 305 hp (227 kW) and 320 ft•lbf (434 N•m)
2004 Ford Mustang Mach 1, 310 hp (231 kW) and 335 ft•lbf (454 N•m)
2003-2004 Mercury Marauder, 302 hp (225 kW) and 318 ft·lbf (431 N·m)
2003-2005 Lincoln Aviator, 302 hp (225 kW) and 318 ft•lbf (431 N•m)
Vehicles equipped with the iron-block 32-valve DOHC 4.6 include the following:

2003-2004 Ford Mustang SVT Cobra, Supercharged, 390 hp (291 kW) and 390 ft•lbf (528 N•m)


5.4 L

The 5.4 L (5409 cc, 330 in³) V8 is a member of the Modular engine family first introduced in the redesigned 1997 Ford F-150 as a Triton V8. Bore diameter is 90.2 mm (3.552 in) and stroke is 105.8 mm (4.165 in), the increased stroke necessitated a taller 256 mm (10.079 in) engine block deck height. The 5.4 L uses a 169.1 mm (6.658 in) connecting rod length to achieve a 1.60:1 rod to stroke ratio. The 5.4 L is built in Windsor, Ontario at the Windsor Engine plant. The 5.4 L has been available in three different configurations since its 1997 introduction:


Modular 5.4 L 4-valve DOHC S/C V8 in a 2007 Ford Shelby GT500SOHC 2-valve
SOHC 3-valve with VCT
DOHC 4-valve

2-valve
Introduced in 1997, the SOHC 2-valve 5.4 L has a cast iron engine block and aluminum cylinder heads. The 5.4 L features multi-port fuel injection, roller rockers, fracture-split powder metal connecting rods, and a forged steel crankshaft.

1997-2004 Ford F-Series, 2-valve SOHC, 260 hp (194 kW) and 350 ft·lbf (475 N·m) (1999 and later model years)
1997-2004 Ford Expedition, 2-valve SOHC, 260 hp (194 kW) and 350 ft·lbf (475 N·m) (1999 and later model years)
1997-present Ford E-Series, 2-valve SOHC, 255 hp (190 kW) and 350 ft·lbf (475 N·m) (1999 and later model years)
1999-2004 Ford Lightning, 2-valve SOHC, Supercharged, 380 hp (283 kW) and 450 ft·lbf (610 N·m) (2001 and later model years)

3-valve
In 2003, Ford introduced a new 3-valve SOHC cylinder head with variable camshaft timing (VCT), improving horsepower and torque over the previous 2-valve SOHC version. The 3-valve cylinder head was first used on the 2003 Ford Fairmont 5.4 L Barra 220 engine in Australia.[4] The 3-valve 5.4 L was introduced to the North American market in the redesigned 2004 Ford F-150.

2003-2005 Ford Fairmont, 3-valve SOHC, 295 hp (220 kW) and 347 ft·lbf (470 N·m)
2003-2004 Ford Fairlane G220, 3-valve SOHC, 295 hp (220 kW) and 347 ft·lbf (470 N·m)
2004-2008 Ford F-Series, 3-valve SOHC, 300 hp (224 kW) and 365 ft·lbf (495 N·m)
2005-present Ford Expedition, 3-valve SOHC, 300 hp (224 kW) and 365 ft·lbf (495 N·m)
2005-present Lincoln Navigator, 3-valve SOHC, 300 hp (224 kW) and 365 ft·lbf (495 N·m)
2005-2007 Ford Fairlane G8, 3-valve SOHC, 309 hp (230 kW) and 369 ft·lbf (500 N·m)
2006-2007 Ford Fairmont, 3-valve SOHC, 309 hp (230 kW) and 369 ft·lbf (500 N·m)

4-valve
In 1999, Ford introduced the DOHC 4-valve 5.4 L in the Lincoln Navigator as a Intech V8. Ford later used DOHC 4-valve 5.4 Ls in the 2000 Mustang SVT Cobra R, the Ford GT supercar, and the Shelby Mustang GT500. The DOHC 4-valve 5.4 L is also used in the Ford Falcon line in Australia under the name Boss.


Modular 5.4 L 4-valve DOHC V8 in a 2000 Ford Mustang SVT Cobra RThe Ford GT version of the 5.4 L is a highly-specialized version of the Modular engine. It is an all-aluminum, dry-sump 5.4 L 4-valve DOHC with a Lysholm screw-type supercharger and showcases numerous technological features, such as dual fuel injectors per cylinder and oil squirters for the piston skirts, not found in other Ford Modular engines. It is rated at 550 hp (410 kW) and 500 ft•lbf (678 N•m), though independent tests conducted on chassis dynamometers have shown these numbers to be very conservative, with GTs often producing nearly 550 hp at the rear wheels. The Shelby GT500 uses an iron block 4-valve DOHC 5.4 L with an Eaton M122H Roots-type blower and air-to-liquid intercooler.

1999-2004 Lincoln Navigator, 4-valve DOHC, 300 hp (224 kW) and 355 ft·lbf (481 N·m)
2000 Ford Mustang SVT Cobra R, 4-valve DOHC, 385 hp (287 kW) and 385 ft·lbf (522 N·m)
2002-2005 Ford Falcon XR8, 4-valve DOHC, 349 hp (260 kW) and 369 ft·lbf (500 N·m)
2005-2006 Ford GT, 4-valve DOHC, Aluminum Block, Supercharged, 550 hp (410 kW) and 500 ft·lbf (678 N·m)
2006-2007 Ford Falcon FPV GT Boss 290, 4-valve DOHC, 389 hp (290 kW) and 384 ft·lbf (521 N·m)
2007-present Ford Shelby GT500, 4-valve DOHC, Supercharged, 500 hp (373 kW) and 480 ft·lbf (651 N·m) SAE J1349 certified
2008-2009 Ford Falcon GT Cobra, 4-valve DOHC, 405 hp (302 kW) and 398 ft·lbf (540 N·m)


6.8 L V10

The 6.8 L (6761 cc, 412 in³) V10 is another variation of the Modular family created for use in large trucks. Bore size is 90.2 mm (3.552 in) and stroke is 105.8 mm (4.165 in), identical the 5.4 L V8. Both 2-valve and 3-valve versions are currently produced. The 6.8 L uses a balance shaft to quell vibrations inherent to a 90° bank angle V10 engine configuration. The 2-valve version, built at Ford's Windsor, Ontario LVL engine line, was first introduced in 1997. For 2005, Ford introduced a 3-valve version of the 6.8 L V10. This is built alongside the 2-valve engine at Ford's Windsor, Ontario engine plant.

Vehicles equipped with the 6.8 L V10 Modular engine include the following:


2-valve
1997-present Ford E-Series, 2-valve SOHC, 305 hp (227 kW) and 420 ft·lbf (569 N·m) (ratings for 2001 and later model years)
1999-2004 Ford F-Series Super Duty, 2-valve SOHC, 310 hp (231 kW) and 425 ft·lbf (576 N·m) (ratings for 2001 and later model years)
2000-2005 Ford Excursion, 2-valve SOHC, 310 hp (231 kW) and 425 ft·lbf (576 N·m) (ratings for 2001 and later model years)

3-valve
2005-present Ford F-Series Super Duty, 3-valve SOHC, 362 hp (270 kW) and 457 ft·lbf (620 N·m).
 

Jrgunn5150

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Awesome, but why oes the 4v part completely skip the early 90's Mark VIII's and FWD Lincolns?
 

SRT Handz

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Jrgunn5150 said:
Awesome, but why oes the 4v part completely skip the early 90's Mark VIII's and FWD Lincolns?

the 4.6 DOHC was never used in FWD lincolns
 

Jrgunn5150

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SRT Handz said:
Jrgunn5150 said:
Awesome, but why oes the 4v part completely skip the early 90's Mark VIII's and FWD Lincolns?

the 4.6 DOHC was never used in FWD lincolns

The Towncar is FWD, and you can't use the block. Anyway, it look's like I read it wrong, so disregard me, excellent write up :thumb:
 

SRT Handz

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Jrgunn5150 said:
The Towncar is FWD, and you can't use the block. Anyway, it look's like I read it wrong, so disregard me, excellent write up :thumb:

sorry but your wrong. Towncar is based on the same Full size platform as the Crown Victoria and Grand Marque, which are RWD.....The Lincoln Town Car has NEVER been FWD
 

Jrgunn5150

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You are right, it's the Continental I was thinking of, my bad.
 

SRT Handz

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Jrgunn5150 said:
You are right, it's the Continental I was thinking of, my bad.

Now your Correct O0 :boink: :dancing6:
 

Jrgunn5150

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:slap:

Maybe we can add in interchangeability list's? I might work on that tomarrow, since I have free time
 
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AaRoN

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Jrgunn5150 said:
:slap:

Maybe we can add in interchangeability list's? I might work on that tomarrow, since I have free time
That'd be good. I thought about it. But what I did so far was already alot so I decided against it considering all the pi swap topics we have and 5.4 swap topics.
 

Jrgunn5150

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That's why I figured on it, lol. Everyday someone want's to swap in a Cobra motor.
 
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AaRoN

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Jrgunn5150 said:
That's why I figured on it, lol. Everyday someone want's to swap in a Cobra motor.

Yup. Ya know from that info a forged '99-01 4V motor with a blower would be better than the actually termy motor cause it's aluminum ;D
 

Dairy King

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So whats it mean when someone says a "non-pi" motor or whatever?
 

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