Ford Modular engine

Ford Modular V8
Manufacturer	Ford Motor Company
Also called:	Ford Triton V8 Ford Triton V10 Lincoln InTech
Production:	1991–present
Predecessor:	Ford Windsor V8 Ford 385 V8
Successor:	Ford Boss engine

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 but additional capacity was added in Windsor, Ontario.

4.6 L

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. 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,^[2] 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.^[3] 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 GT

Vehicles equipped with the cast iron 16-valve SOHC 4.6 include the following:

• 1991-1993 Lincoln Town Car, 190 hp (Expression error: Unrecognised punctuation character "{" kW) and 260 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1992-1997 Ford Crown Victoria/Mercury Grand Marquis, 210 hp (Expression error: Unrecognised punctuation character "{" kW) and 270 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) with dual exhaust option
• 1998-2000 Ford Crown Victoria/Mercury Grand Marquis, 215 hp (Expression error: Unrecognised punctuation character "{" kW) and 270 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) with dual exhaust option
• 2001-2002 Ford Crown Victoria/Mercury Grand Marquis, 235 hp (Expression error: Unrecognised punctuation character "{" kW) and 275 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) with dual exhaust option
• 2003-2004 Ford Crown Victoria/Mercury Grand Marquis, 239 hp (Expression error: Unrecognised punctuation character "{" kW) and 282 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) with dual exhaust option
• 2004-present Ford Crown Victoria Police Interceptor, 250 hp (Expression error: Unrecognised punctuation character "{" kW) and 287 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1994-1997 Lincoln Town Car, 210 hp (Expression error: Unrecognised punctuation character "{" kW)
• 1994-1995 Ford Thunderbird, 205 hp (Expression error: Unrecognised punctuation character "{" kW) and 265 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1996-1997 Ford Thunderbird, 205 hp (Expression error: Unrecognised punctuation character "{" kW) and 280 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1994-1995 Mercury Cougar, 205 hp (Expression error: Unrecognised punctuation character "{" kW) and 265 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1996-1997 Mercury Cougar, 205 hp (Expression error: Unrecognised punctuation character "{" kW) and 280 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1998-2000 Lincoln Town Car, 205 hp (Expression error: Unrecognised punctuation character "{" kW)
• 2001-2002 Lincoln Town Car, 235 hp (Expression error: Unrecognised punctuation character "{" kW)
• 2003-2004 Lincoln Town Car, 239 hp (Expression error: Unrecognised punctuation character "{" kW)
• 2002-2005 Ford Explorer, 239 hp (Expression error: Unrecognised punctuation character "{" kW) and 282 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1996-1997 Ford Mustang, 215 hp (Expression error: Unrecognised punctuation character "{" kW) and 285 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1998 Ford Mustang, 225 hp (Expression error: Unrecognised punctuation character "{" kW) and 290 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1999-2004 Ford Mustang, 260 hp (Expression error: Unrecognised punctuation character "{" kW) and 302 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1997-present Ford F150, 248 hp (Expression error: Unrecognised punctuation character "{" kW) and 294 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 2007 and later model year F150s

Modular 4.6L 3-valve SOHC V8 in a 2006 Ford Mustang GT

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 (see below), 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 2008. 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 Cobra

Vehicles equipped with the all aluminum 32-valve DOHC 4.6 include the following:

• 1993-1998 Lincoln Mark VIII, 280 hp (Expression error: Unrecognised punctuation character "{" kW) and 285 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1995-1997 Lincoln Continental, 260 hp (Expression error: Unrecognised punctuation character "{" kW) and 265 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1996-1998 Ford Mustang SVT Cobra, 305 hp (Expression error: Unrecognised punctuation character "{" kW) and 300 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1997-1998 Lincoln Mark VIII LSC, 290 hp (Expression error: Unrecognised punctuation character "{" kW) and 290 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1998-2002 Lincoln Continental, 275 hp (Expression error: Unrecognised punctuation character "{" kW) and 275 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 1999/2001 Ford Mustang SVT Cobra, 320 hp (Expression error: Unrecognised punctuation character "{" kW) and 317 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2003-2004 Mercury Marauder, 302 hp (Expression error: Unrecognised punctuation character "{" kW) and 318 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2003 Ford Mustang Mach 1, 305 hp (Expression error: Unrecognised punctuation character "{" kW) and 320 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2004 Ford Mustang Mach 1, 310 hp (Expression error: Unrecognised punctuation character "{" kW) and 335 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2003-2004 Mercury Marauder, 302 hp (Expression error: Unrecognised punctuation character "{" kW) and 318 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2003-2005 Lincoln Aviator, 302 hp (Expression error: Unrecognised punctuation character "{" kW) and 318 ft·lbf (Expression error: Unrecognised punctuation character "{" 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 (Expression error: Unrecognised punctuation character "{" kW) and 390 ft·lbf (Expression error: Unrecognised punctuation character "{" 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 GT500

• SOHC 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 (Expression error: Unrecognised punctuation character "{" kW) and 350 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 1999 and later model years
• 1997-2004 Ford Expedition, 2-valve SOHC, 260 hp (Expression error: Unrecognised punctuation character "{" kW) and 350 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 1999 and later model years
• 1997-present Ford E-Series, 2-valve SOHC, 255 hp (Expression error: Unrecognised punctuation character "{" kW) and 350 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 1999 and later model years
• 1999-2004 Ford Lightning, 2-valve SOHC, Supercharged, 380 hp (Expression error: Unrecognised punctuation character "{" kW) and 450 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 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 (Expression error: Unrecognised punctuation character "{" kW) and 347 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2003-2004 Ford Fairlane G220, 3-valve SOHC, 295 hp (Expression error: Unrecognised punctuation character "{" kW) and 347 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2004-2008 Ford F-Series, 3-valve SOHC, 300 hp (Expression error: Unrecognised punctuation character "{" kW) and 365 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2005-present Ford Expedition, 3-valve SOHC, 300 hp (Expression error: Unrecognised punctuation character "{" kW) and 365 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2005-present Lincoln Navigator, 3-valve SOHC, 300 hp (Expression error: Unrecognised punctuation character "{" kW) and 365 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2005-2007 Ford Fairlane G8, 3-valve SOHC, 309 hp (Expression error: Unrecognised punctuation character "{" kW) and 369 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2006-2007 Ford Fairmont, 3-valve SOHC, 309 hp (Expression error: Unrecognised punctuation character "{" kW) and 369 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)

4-valve

In 1999, Ford introduced the DOHC 4-valve 5.4 L in the Lincoln Navigator as an 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 R

The 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 (Expression error: Unrecognised punctuation character "{" kW) and 355 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2000 Ford Mustang SVT Cobra R, 4-valve DOHC, 385 hp (Expression error: Unrecognised punctuation character "{" kW) and 385 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2002-2005 Ford Falcon XR8, 4-valve DOHC, 349 hp (Expression error: Unrecognised punctuation character "{" kW) and 369 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2005-2006 Ford GT, 4-valve DOHC, Aluminum Block, Supercharged, 550 hp (Expression error: Unrecognised punctuation character "{" kW) and 500 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2006-2007 Ford Falcon FPV GT Boss 290, 4-valve DOHC, 389 hp (Expression error: Unrecognised punctuation character "{" kW) and 384 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m)
• 2007-present Ford Shelby GT500, 4-valve DOHC, Supercharged, 500 hp (Expression error: Unrecognised punctuation character "{" kW) and 480 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) SAE J1349 certified
• 2008-2009 Ford Falcon GT Cobra, 4-valve DOHC, 405 hp (Expression error: Unrecognised punctuation character "{" kW) and 398 ft·lbf (Expression error: Unrecognised punctuation character "{" 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 (Expression error: Unrecognised punctuation character "{" kW) and 420 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 2001 and later model years
• 1999-2004 Ford F-Series Super Duty, 2-valve SOHC, 310 hp (Expression error: Unrecognised punctuation character "{" kW) and 425 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 2001 and later model years
• 2000-2005 Ford Excursion, 2-valve SOHC, 310 hp (Expression error: Unrecognised punctuation character "{" kW) and 425 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) ratings for 2001 and later model years

3-valve

• 2005-present Ford F-Series Super Duty, 3-valve SOHC, 362 hp (Expression error: Unrecognised punctuation character "{" kW) and 457 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m).

5.0 L Cammer

Modular 5.0 L R50 "Cammer" 4-valve DOHC V8 engine installed in a Grand-Am Cup Mustang FR500C.

In 2005, Ford Racing Performance Parts introduced a 5.0 L (4992 cc, 305 in³) V8 crate engine for use in motor racing and home-made performance cars, officially called M-6007-T50EA, but more widely known as "Cammer". FRPP developed the Cammer from the previous generation's aluminum 4-valve DOHC engine. The Cammer employs a 3.700" bore (3.552" is stock for Modulars) achieved by re-sleeving the aluminum block to reach its 5.0 L of displacement. The M-6007-T50EA Cammer crate engine utilizes cylinder heads, a dual runner magnesium intake manifold, and camshafts not found in other 4V production or crate engines. The Cammer that has seen success in Grand Am Cup — officially called M-6007-R50 — highlights a unique dual plenum, fixed runner intake manifold, Ford GT aluminum cylinder heads, unique camshafts, and an 11.0:1 compression ratio. The 5.0 L Cammer is used mainly in Mustang racing cars in the Grand-Am Cup and the SCCA World Challenge's GT class, but can be installed in a variety of other applications, including road cars, dragsters and sports car racing prototypes. Upon introduction the Cammer-powered Mustang proved to be dominant in Grand-Am Cup, having achieved five victories and podium appearances in nearly every race in the GS class during the 2005 season, giving David Empringham the championship title with the Multimatic Motorsports team, and Ford the manufacturer's title. Robert Yates publicly expressed interest in using a similar 5.0 L 4-valve DOHC Modular V8 to compete in the NASCAR Winston (now NEXTEL) Cup series.^[5][6][7] Roush-Yates currently supplies a 550 hp 5.0 L Cammer for the Mustang FR500GT that participates in FIA GT3 European Championship.^[8]

Ford of Australia

Ford Australia uses 5.4 L Modular V8s in the Ford Falcon and Ford Fairlane sedan model ranges, as well as in its high performance Ford Performance Vehicles (FPV) division models. The DOHC 5.4 L V8s are coined Boss by Ford Australia while the SOHC versions are coined Barra, with a number designation referring to power output in kW. The SOHC Barra engines and the DOHC Boss shortblocks and cylinder heads are built in Windsor, Ontario. The Boss engines include some locally sourced parts such as intake and pistons. All are built with cast-iron blocks. Ford of Australia 5.4 L engines include:

• Barra 220 3-valve SOHC 5.4 L V8, 295 hp (Expression error: Unrecognised punctuation character "{" kW) @ 4750 rpm, 347 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) @ 3250 rpm
• Barra 230 3-valve SOHC 5.4 L V8, 309 hp (Expression error: Unrecognised punctuation character "{" kW) @ 5350 rpm, 369 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) @ 3500 rpm
• Boss 260 4-valve DOHC 5.4 L V8, 349 hp (Expression error: Unrecognised punctuation character "{" kW) @ 5250 rpm, 369 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) @ 4000 rpm
• Boss 290 4-valve DOHC 5.4 L V8, 389 hp (Expression error: Unrecognised punctuation character "{" kW) @ 5500 rpm, 384 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) @ 4500 rpm
• Boss 302 4-valve DOHC 5.4 L V8, 405 hp (Expression error: Unrecognised punctuation character "{" kW) @ 6000 rpm, 398 ft·lbf (Expression error: Unrecognised punctuation character "{" N·m) @ 4800 rpm

World Record

The Koenigsegg CCR used a modified, Rotrex supercharged Ford Modular 4-valve DOHC 4.7L V8, which produced 806 hp (601 kW), to achieve a top speed of 241 mph (388 km/h). This certified top speed broke the McLaren F1's long standing world record for fastest production car. The accomplishment was recognized by Guinness World Records in 2005, who gave the Koenigsegg CCR the official title of Worlds Fastest Production Car. This engine is the basis for Koenigsegg's twin-supercharged flexible fuel V8 seen in the CCX. The Koenigsegg record was broken several months later by the Bugatti Veyron.

Intake Manifold Defect

Starting in 1996, Ford began installing a DuPont Zytel nylon-composite intake manifold onto the 2-valve SOHC engines which were found to crack at the front coolant crossover, leaking coolant and possibly causing engine failure. A class-action suit was filed on behalf of owners, resulting in a settlement announced on December 17, 2005. Starting with the 2002 model year, Ford began using a revised DuPont Zytel nylon-composite intake manifold with an aluminum front coolant crossover that corrected the issue. Replacement intakes were also made available for 1996-2001 engines.^[9][10] The following vehicles were included in this class-action suit settlement:

• Mercury Grand Marquis, 1996-2001
• Lincoln Town Car, 1996-2001
• Ford Crown Victoria, 1996-2001
• Mercury Cougar, 1997 (Build date after 6/24/97)
• Ford Thunderbird, 1997 (Build date after 6/24/97)
• Ford Mustang, 6/24/1997-2001 (some vehicles)
• Ford Explorer, early 2002

References

See also

• List of Ford engines
• List of Ford factories