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They are all patterened after each other. The 4.6 and 5.4 are almost identical as the bore is the same but the stroke on the 5.4 is deeper. The V10 is the same bore also but is stretched with two exta cylinders and I am not sure about the stroke. They wanted a modular V6 also but never went through with it and settled on the 4.2 liter. The V6 they envisioned would probably have the same bore too. They also can interchange a few parts and have a different design mechanically than old pushrod engines. They have more reenforcement in the center of the engine where the old engines had their pushrods I think.
I dont know about tougher but I have heard the design of the block has more structural integrity. This came about for me when I was talking to an old car buff and he said they were reenforced more in certain areas where old parts no longer had to take up open space such as pushrods. As far as longevity I think personally they are better in most cases and are this way due to computers and tolerences. They are a great design and the 4.6 is a bulletproof motor in most cases when it isn't abused. It was primarily a cost efficency move for Ford as they could use the same parts and machines on building similar engines.
The Modular Engine was desiged to use less tooling and be of greater benfit to more vehicles.
It was made for 4, 6, and 8 cylinder models.
The same boring machine is used for all sizes so bores are identical.
Ford was trying to save money.
The eight cylinder model pivots 90 degrees so it can do both banks. The 4 cylinder did not need to pivot. The six cylinder model pivited 60 degrees.
There were supposed to be 2.3 liter 4 cylinder motors, 3.45 liter called the 3.5 liter and the 4.6 Liter engines. All crank lengths are the same so the same machines can do the crank work and cam work.
Modular refered more to the way they could be machined on the same mechanism for all engines.
There was an article in popular science or mechanics a while ago on the machines to make the motors.
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