Motor is 2000, pulleys are the same size as far as I can tell, haven't measured but they look the same size. Oil filters were the same. Only difference so far was the intake manifolds, throttle body coolant lines vs vacuum lines. my truck had coolant lines going to the side of the elbow, the 00 has 3 vacuum lines in its place. I plan on using the newer throttle body/IAC/elbow since they are in much better shape.

I'll pull the plugs out and clean them a bit (where can i find dentured alcohol?), it was only a few that I accidentally, while pulling out the oil squirter nozzle got some oil on the threads. The plugs I pulled out of the motor were the originals and in great shape but I decided to change them with the nickle plated plugs.

The box... Hrmm, are there any mods to do to the box? lol, looks like an odd design, was all that just to keep the intake noise down? I should probably leave it alone but it looks interesting.

48.. your still young. I'm not trying to break any records but it is my daily driver so Ive been pushing to get it done. I'm sure I lost a few bolts with as many that were flying off.
I haven't got to the fun part of the install yet...I'm sure that will be a solid 7-10hrs tomorrow.

I will 100% agree on the difficulty. This is the first v8 I've done and.. well.. its big. Nothing like having that big chunk of metal hanging above your head. The size of this thing is unreal. The amount of fluids that came out weigh more than my dirtbike. The buddy that is letting me use his garage sais that my motor sits bigger on the stand than his 460 did. Due to the shape of the motor.

Thanks

 

Dentured alcohol can be found at any pharmacy or drug store. It's a good oil/grease cutter. Also the best MAF cleaner on the market when cleaned correctly. Auto supplies sell a Paint Prep cleaner that works very well, -more expensive tho - and that also works on the MAF. So either product will clean the plug threads right up.

When you have to play around with vacuum lines, here's the proper way to connect or splice -



Also, be careful when working with the vac elbow boots , -if you push them to far in they will not flow. Test when building or rebuilding a vac harness.

 

Only difference is 6 or 8 rib belt/pulley

 

pulleys are the same luckily. checked them today. got the motor in, took a good 3.5 hrs to get it in and bolted up. everything is back on but the intake manifold (gaskets didn't come in today) and everything that goes with it. Hoping maybe another 4 hours and it will be driving.


I do have a question about the throttle bodies. I want to use the newer one but there are some differences. You can see here. The old one from my 99 has the pcv valve connecting to the other tubes that run into a splitter. On the newer one, there are vacuum hoses there. Same vacuum setup from the other truck but is routed differently at different lengths. Not sure if I can swap them or not. Then I thought, ill just clean the old one and put the new IAC and egr on the older elbow. But then what would I do with the coolant lines that used to run to the elbow? Not sure. Also there is a second tube on the older elbow that the newer one doesnt have. Looks like on my old motor it used to run to the drivers side pcv valve and the hose that said "gas" on it.

 

I dunno.. I swapped intakes kept my old one. I kept the intake and throttle body off the new engine though. I think it could be made to work. Looks like they heat the PVC with engine water on the new ones. thats the big difference. You could either make it work like it suppose to or plug the water lines and use the old pvc and it lines..

 

Yah, I think I'm going to find a way to make the newer throttle body and elbow work with my old intake manifold. So far it looks like worse case is I'll have to use that thrifty diagram to splice and lengthen a few vacuum hoses and plug a few hoses. Crazy how many little things they changed on the production line in 1 year, all that seem to change nothing really. Hopefully hear some noise come out of the beast tomorrow evening.

 

Change from year to year? Heck, I think Ford changes some things over noon hour. It's always been that way with them, but a lot of others too.

 

Yea that's just the Cold Climate System. The new engine should have came with a wrapped PCV line, - CCS systems did without. You can by-pass that tree by just connecting the lines together. The PCV side has nothing to do with coolant. It's dry line that captures the heat. Green circle is a brake booster assist port. Above that , another vac (could be used as a main vac as well) - You have options lol.

If you have a 99 5.4L manifold tho, - I would use that for sure, - best one ford had in the 2v 5fours.

 

Yah, I'm using the 99 intake manifold. And it does have a wrapped single pcv line. Think I got it figured out. Only thing is In the green circled part on the right (old 99 elbow) where does the top hose go to, cause on the newer 1, there is only the line for the brake booster.

 

So is this a 4.6 to 5.4 swap or a 4.6 to newer 4.6 swap?

 

99 5.4 (knocking) to 00 5.4 (10k miles)

 

Yea, -hard to picture the explanation without pictures lol.

Yellow - EVAP
Red - Main Vac
Green - Booster (assist )
Blue - Coolant Tree ( some models )









As you can see, main vac be on either side. Like I said before, you can eliminate the coolant tree by connecting the by pass hoses. Ford eliminated it and sleeved the PCV line instead with later models.

Choice is yours depending upon what vac harnesses you have in possession. You can make your own, that's why I posted the how to for you from Service and Repair.

 

Gotcha, went ahead and used the newer throttle body and my old metal intake. So I swapped everything over to the newer setup as far as the hoses and vac setup went. Everything worked out alright, had to swap a few things around like the pcv elbow at the back of the intake manifold wasnt long enough. Motor is in, fired right up and sounds great. Has a missfire though. Stupid me thought it would be better to use the injectors from the newer motor not thinking that they had been sitting for so many years. There was still old gas in them and I only cleaned the outer serfaces of them. I'm sure theyre gummed up with old nasty gel gas. Ill have to run some cleaner through them or wait for it throw a code.

 

I can't remember, -well I sortuh recall the PCV ports changed at some point.

There was a manifold PCV port/inlet earlier, then it changed to the TB Elbow/Plenum ? Must have changed in 2000 Huh. Yea, must have just been in the aluminum 5four manifolds (97-99), -non PI's are the same way. When they went composit (2000) , the PCV jumped to the plenum (TB elbow).

Did you notice a MIL or a CEL, is it missing bad enough ? You have a scanner ?

 

It's definitely missing pretty bad, truck noticeably shakes. No Mil or CEL yet...going to drive it more today though. Stumbles pretty hard when put into gear or under load. Idle is right at 750, oil pressure is good, changed it with 5/20 castrol and Motorcraft filter just before start up.

I was going over everything in my head that it could be. Thinking its the 10 year old injectors that sat with old gas. I bought all new lower and upper intake manifold gaskets, set and torqued them properly, 3 times. Will check again today though, 20in/lbs didn't seem like much. All surfaces were cleaned. New egr, throttle body and IAC gasket. Intake is cleaned. Cleaned each injector seat. All hoses were inspected for cracks. New pcv valve. New plugs, dialectric grease on the cop boots...which I have a question about. How is it certain the tip of the boot slips over the end of the plug if the boot that slides down into the plug chamber is a lot smaller in diameter than the chamber? Could 1 of them not be set over the plug and maybe off to the side?

I don't have a scanner but have access to one if needed