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Twin
Port Head
Dimensions (Intake)
Square Port 32mm x 40mm
Oval Port 36mm x 44mm |
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1999
& Later 4.6L Tumble Port (Intake)
50mm x 39mm |
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1998
& Later 5.4L Tumble Port (Intake)
59mm x 39mm |
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All DOHC Exhaust Ports
48mm x 25mm
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Cooling
System
The
4.6L, 5.4L & 6.8L cast iron blocks use a cooling system that
is different from the one that is used on the aluminum blocks. The
aluminum blocks use a bypass hose (this is the hose that runs in
front of the engine to the thermostat housing) to keep flow constant
through the block to help eliminate hot spots. This is due to aluminum
being more susceptible to hot spots than is cast iron. If you are
running an aluminum block do not eliminate this hose. The cast iron
blocks utilize a conventional cooling system (no bypass hose).
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Oil
System
The oil pump used on modular engines is what's referred to as a
gerotor pump. It contains two internal gears with the middle one
being driven by the crank. The clearance between the sides of the
gears and the internal sides of the oil pump are critical. These
pumps are not as robust as the pumps used on the older push rod
Ford's. If any debris gets into the oil pump it will gall the sides
of the aluminum housing, creating a situation where the pump will
not prime. If you are reusing an oil pump be sure to pull the cover
off the pump for a close inspection of the housing for galling.
Replacing this pump after installation of the engine is not a fun
job.
There have also been failures of the powdered metal gears utilized
in these pumps when used in
hi-performance applications. There are billet pump gears being offered
by some vendors to address this problem, do a search on Google and
you will come up with several suppliers.
FRPP also offers a high volume oil pump. It is available under part
# M-6600-D46 for 59.95. This pump is the same unit as is used in
the Cobra's and does not have billet gears. |
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Engine
Weights and Dimensions |
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Engine |
Weight |
| 4.6L
SOHC |
500 lbs. |
| 5.4L
SOHC |
525 lbs |
| 4.6L
DOHC Aluminum Block |
425 lbs |
| 5.4L
DOHC |
540 lbs |
| 6.8L
SOHC V-10 |
640 lbs. |
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| Accurate
weights are hard to come by. It seems everyone has their own idea
of what constitutes an engine assembly. Was it weighed with all
the accessories, was it dry or filled with fluids, etc. Use
this as a guide, these numbers are close but will vary from what
you see elsewhere. |
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Dimension
A measures from the top of the throttle body pad (if you
are running our intake) or top of the factory intake (if stock)
to the bottom of the factory oil pan.
Dimension B measures from the bell housing face
to the front of the water pump pulley.
Dimension C measures from the outside edge of each
cylinder head. |
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Engine |
"A" |
"B" |
"C" |
| 4.6L
SOHC Mustang Intake |
* |
23
5/8" |
* |
| 5.4L
SOHC F-Series Intake |
28
" |
23
5/8" |
* |
| 4.6L
DOHC Cobra Intake |
27
1/8" |
23
5/8" |
26
5/8" |
| 4.6L
DOHC Sullivan Intake |
27
3/4" |
23
5/8 |
26
5/8" |
| 5.4L
DOHC Navigator Intake |
35
1/2" |
23
5/8" |
28
1/4" |
| 5.4L
DOHC Sullivan Intake |
28
1/2" |
23
5/8" |
28
1/4" |
| 6.8L
SOHC V-10 Van Intake |
28
1/2" |
27
1/8" |
* |
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Water
Outlet / Oil Filter Mount
According
to Babcox there have been at least 6 different castings for the
water outlet / oil filter mount. These castings are interchangeable
for all of the modular engines. The one you will probably want
to use is found on the Cobras and some Mustangs. You can get it
at your Ford dealer under part # F8ZZ6881AA. It retails for about
150.00. This casting accepts a factory oil cooler that also doubles
as your water outlet, the water outlet exits above the power steering
pump. The factory cooler is also available from Ford under part
# F8ZZ6A642BA, it sells for about 150.00.
If you are running our 5.4L single plane intake and opted to relocate
the alternator with our bracket, you will need the oil cooler
housing off the 2003 cobra. The water outlet on this housing exits
below the power steering pump. This cooler is available under
part # 2R3Z6A642AA for about 150.00. |
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Engine
Mounts
All of the
modular engines have the same basic mounting locations on the
cylinder block. This means you can take the mounts off a 4.6L
Mustang Cobra, bolt them onto a 5.4L Navigator engine and bolt
the engine directly onto the factory cross member. This scenario
also applies to the 6.8L V-10, 5.4L SOHC, or the 4.6L SOHC.
The only exception to this is the Continental blocks previously
discussed. For your information the Cobra R model used motor mounts
that lowered the engine in the chassis 12mm, It did however, bolt
onto the standard Mustang cross member. Something to think about
if you are having hood clearance issues. If you are a
Mustang owner and want to go with a tubular cross member we very
highly recommend Anthony Jones Engineering. Their cross members
fit perfect and the quality is the best on the market. They can
be reached
at http://www.ajeracing.com |
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Exhaust
The 4.6L &
5.4L share the same exhaust port configuration. You can use a
pair of Cobra shorty headers for your 5.4L DOHC transplant if
you wish. None of the long tube headers currently available for
the DOHC Cobra will work with the 5.4L swap inside a Mustang without
modification. There are no commercially available swap headers
at this time. Same thing goes for the 4.6L & 5.4L SOHC. There
are several company's making shorty headers for the V-10, do a
Google search for "Ford V-10 headers" and several will
come up. |
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If
you have some good technical information for these pages, we would
appreciate your sharing it with the rest of the modular community.
Your contributions are what will help grow this database. You can
e-mail your information (we will post with the information, who
provided it) or questions regarding this database to: tech@sullivanperformance.com |
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