2000-01 CYLINDER BLOCK ASSEMBLY 5.4L V8 – VIN L

Piston & Rod Assembly
Note direction of connecting rod installation on piston. Install piston and connecting rod in engine, with arrow
on top of piston toward front of engine.

Fitting Pistons
1. Standard service pistons are coded 1, 2 and 3 on dome of piston. Measure piston skirt diameter at 90-
degree angle to piston pin, 1.62″ (42.0 mm) below piston top. Replace piston if piston diameter is not
within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore at .50″ (12.7 mm) below top of piston travel and .50″ (12.7 mm) above bottom of
piston travel. Ensure piston clearance is within specification. See PISTONS, PINS & RINGS table.
3. If piston clearance is not within specification, choose a selective fit piston to bring piston clearance within
specification. See PISTONS, PINS & RINGS table, for selective fit piston sizes.
4. If piston clearance cannot be corrected using a selective fit piston, bore all cylinders to nearest oversize.

Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS. Position oil control ring expander with gap positioned straight forward and rails
with gaps 180 degrees apart, aligned with piston pin. Install compression rings with gaps staggered, so ring gaps
do not align.

Rod Bearings
1. Ensure piston and connecting rod are installed in engine with arrow on top of piston toward front of
engine.
2. Check bearing clearances using Plastigage. Ensure bearing oil clearance and side play are within
specification. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS and
CONNECTING RODS tables under ENGINE SPECIFICATIONS. If oil clearance exceeds
specification, grind crankshaft to fit undersize bearings. Tighten connecting rod bearing cap bolts to
specification. See TORQUE SPECIFICATIONS .

Crankshaft & Main Bearings
1. Measure main bearing clearances using Plastigage. Main bearing caps are marked for location, with No. 1
at front, and No. 5 at rear of engine. Arrow on main bearing cap must point toward front of engine.
Lubricate bearing shells with assembly lube or heavy oil before installation.
2. Install main bearing inserts in cylinder block. Lay crankshaft into cylinder block. Push crankshaft
rearward. Roll thrust washer into cylinder block, ensure coating on bearing is facing crankshaft thrust
surface.
3. Install main bearing caps using NEW bolts, do not fully tighten. Using a pry bar, push crankshaft forward
to seat thrust washer. While holding crankshaft forward, evenly pry No. 5 main bearing cap rearward. DO
NOT cock bearing cap. Tighten main bearing cap bolts to specification in 2 steps using proper sequence.
See Fig. 41 . See TORQUE SPECIFICATIONS .
4. Tighten side adjusting screws against cylinder block to specification in 2 steps using proper sequence.
See Fig. 41 . Side adjusting screws have left-hand threads. Tighten side bolts.

Cylinder Block
1. Using a feeler gauge and straightedge, inspect cylinder block deck for warpage. If not within
specification, resurface or replace cylinder block. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS.
2. Check cylinder bore diameter, out-of-round and taper. Cylinder bore is measured at .50″ (12.7 mm) below
top of cylinder block head surface and .50″ (12.7 mm) above piston when at bottom of cylinder bore.
3. Bore cylinder block if measurements are not within specification. See CYLINDER BLOCK table.

01. July 2018 by sam
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2000-01 CYLINDER HEAD OVERHAUL 5.4L V8 – VIN L

Cylinder Head
Check cylinder head for cracks or damage. If maximum warpage exceeds .004″ (.10 mm), replace cylinder
head.

Valve Springs
Inspect valve spring free length, out-of-square and pressure. Replace valve spring if not as specified. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals
Use Seal Installer to install oil seals.

Valve Guides
1. Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available in .015″ (.38 mm)
and .030″ (.76 mm) oversize.
2. Valve guides may also be replaced with a NEW guide if oversize valves are not available or guide is
damaged. Ream valve guides until proper stem-to-guide clearance exists.

Valve Seat
Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table
under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced.
Replacement information is not available.

Valves
Ensure head diameter, stem diameter, valve face runout and valve margin are within specification. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles
If seat width is too wide after grinding seat, use a 75-degree stone to remove stock from bottom of valve seat
(raise seat) or a 30-degree stone to remove stock from top of seat (lower seat).

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2000-01 OIL PAN 5.4L V8 – VIN L

Removal (Expedition, Navigator & Pickup – 2WD)
1. Remove the radiator air deflector screws and remove the radiator air deflector. Remove the generator.
Disconnect the throttle cable, speed control actuator cable and return spring. See Fig. 16 .
2. Remove the throttle cable bracket bolts and position the bracket and cables aside. Disconnect the vapor
management valve hose. Remove the crankcase ventilation tube and the Idle Air Control (IAC) valve
fresh air tube. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum line and the main vacuum
harness.
3. Disconnect the Throttle Position (TP) sensor electrical connector and the engine vacuum regulator
connector. See Fig. 17 . Disconnect the fuel pressure regulator vacuum line. Disconnect the vapor
management valve vacuum line. See Fig. 18 . Remove the brake booster vacuum line bracket bolt and
disconnect the brake booster vacuum line and bracket. See Fig. 19 .
4. Disconnect the differential pressure feedback EGR sensor electrical connector. See Fig. 20 . Remove the
differential pressure feedback EGR sensor nut. See Fig. 21 . Disconnect the IAC motor electrical
connector. Disconnect the upper and lower EGR fittings and disconnect the differential pressure feedback
EGR sensor hoses and position the EGR tube aside. See Fig. 22 .
5. Remove the 4 bolts and remove the throttle body adapter. See Fig. 23 . Remove the fan shroud bolts and
position the fan shroud aside. See Fig. 24 . Install the Engine Lift Bracket (303-639) on the engine using
the generator mounting bolts. See Fig. 25 . Install the Heavy Duty Engine Support (303-F070). See Fig.
26 .
6. Raise and support the vehicle. Remove the starter solenoid terminal cover. Disconnect the starter motor
electrical connectors. Remove the positive battery cable and starter solenoid wire retaining nuts. See Fig.
27 . Remove the ground wire retaining nut and detach the ground wire. See Fig. 28 .
7. Remove the 3 starter retaining bolts and remove the starter. Remove the oil pan drain plug and drain the
engine oil and into a suitable drain pan. Remove the left and right motor mount through bolts. Lower the
vehicle. Raise the engine using the heavy duty engine support. Raise the vehicle on the hoist.
8. Remove the oil pan bolts and position the oil pan aside to gain access to the oil pump screen and pickup
tube retaining bolts. Remove the bolt securing the rear of the oil pump screen and pickup tube. Remove
the bolts securing the front of the oil pump screen and pickup tube. Remove the oil pan and the oil pickup
tube together.

Installation
1. Clean and inspect the mating surfaces. Position the oil pan gasket, the oil pan and the oil pump screen and
pickup tube together to the cylinder block.
2. Install a NEW “O” ring and lubricate with clean engine oil. Position the oil pump screen and pickup tube.
Install oil pump screen and pickup tube retaining bolts. Tighten oil pump screen and pickup tube retaining
bolts to specification. See TORQUE SPECIFICATIONS . Apply silicone gasket and sealant at the
engine front cover to cylinder block mating surface.
3. Apply silicone gasket and sealant at the rear oil seal retainer to cylinder block sealing surface. Position
the oil pan gasket and install the oil pan bolts. Tighten oil pan bolts to specification, in sequence, using
the following 3 stages. See Fig. 29 .
􀁺 Stage 1: Tighten to 18 INCH lbs. (2 N.m).
􀁺 Stage 2: Tighten to 15 ft. lbs. (20 N.m).
􀁺 Stage 3: Tighten an additional 60 degrees. See Fig. 30 .
4. Lower the vehicle. Lower the engine and remove the Heavy Duty Engine Support (303-F070). See Fig.
26 . Raise and support vehicle on the hoist.
5. Install the right and left side motor mount through bolts. Tighten the right and left side motor mount
through bolts. See TORQUE SPECIFICATIONS . Install and tighten the oil pan drain plug to
specification.
6. Install the starter and install the 3 starter retaining bolts and tighten to specification. Connect the ground
cable and install the nut. See Fig. 28 . Connect the starter motor electrical connectors.
7. Position and install the starter solenoid wire and tighten nut to specification. See Fig. 27 . Position and
install positive battery cable to starter solenoid battery cable and tighten nut to specification. See
TORQUE SPECIFICATIONS .
8. Install the starter motor solenoid cover. Lower the vehicle. Remove the Engine Lift Bracket (303-639).
See Fig. 25 . Position the fan shroud. See Fig. 24 . Tighten fan shroud bolts to specification. See
TORQUE SPECIFICATIONS .
9. Install the throttle body adapter and the 4 bolts. Tighten the throttle body adapter bolts in sequence, to
specification, using the following 2 stages. See Fig. 23 .
􀁺 Stage 1: Tighten to 89 INCH lbs. (10 N.m).
􀁺 Stage 2: Tighten an additional 90 degrees. See Fig. 30 .
10. Install the EGR tube to exhaust manifold tube and EGR valve. Hand-tighten the upper and lower fittings.
See Fig. 22 . Tighten the upper and lower EGR tube fittings to specification. See TORQUE
SPECIFICATIONS . Connect the 2 differential pressure feedback EGR sensor hoses.
11. Connect the Idle Air Control (IAC) valve. Install the differential pressure feedback EGR sensor nut and
tighten to specification. See Fig. 21 . See TORQUE SPECIFICATIONS . Connect the brake booster
vacuum line and bracket and install the brake booster vacuum line bracket bolt. See Fig. 19 . Connect the
differential pressure feedback EGR sensor electrical connector. See Fig. 20 .
12. Connect the vapor management valve vacuum line. See Fig. 18 . Connect the fuel pressure regulator
vacuum line. Connect the Throttle Position (TP) sensor connector and the engine vacuum regulator
electrical and vacuum connectors. See Fig. 17 .
13. Connect the EGR valve the main vacuum harness vacuum connections. Install the crankcase ventilation
tube and the IAC fresh air tube. Connect the vapor management hose. Install the throttle cable bracket
and the bolts. See Fig. 16 .
14. Connect the throttle cable, speed control actuator cable and throttle return spring. See Fig. 16 . Install the
generator. See appropriate article in STARTING & CHARGING SYSTEMS. Install the radiator air
deflector. Fill the engine to proper level with appropriate engine oil.

Removal (Expedition, Navigator & Pickup – 4WD)
1. Turn the air suspension switch off. Air suspension switch is located behind right kick panel. Raise and
support the vehicle on a hoist. On vehicles equipped with the Dual Overhead Camshaft (DOHC), remove
the front axle assembly. See appropriate article in DRIVE AXLES. On all vehicles, remove oil pan drain
plug and drain the engine oil into a suitable drain pan. Install oil pan drain plug and tighten to
specification. See TORQUE SPECIFICATIONS .
2. On vehicles equipped with a Single Overhead Camshaft (SOHC), support the front axle housing with a
jack stand and remove the front axle mount bolt and axle support bolts. See Fig. 31 . Remove the front
axle support from vehicle. Remove the right and front axle housing mount bolts and lower the axle to
allow clearance for the oil pan to be removed. See Fig. 32 .
3. On all vehicles, remove the oil pan bolts and remove the oil pan. Discard the oil pan gasket. Inspect the
oil pan for damage and replace as necessary. Using Metal Surface Cleaner (F4AZ-19A536-RA), clean the
sealing surfaces. Allow the sealing surfaces to dry for 4 minutes or until there is no sign of wetness,
whichever is longest. Failure to do so can cause future oil leaks.

01. July 2018 by sam
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2000-01 WATER PUMP5.4L V8 – VIN L

Removal & Installation
1. Drain cooling system. Remove cooling fan and fan shroud. Remove accessory drive belt. Remove water
pump pulley. Remove water pump retaining bolts. Remove water pump and “O” ring.
2. To install, reverse removal procedure. Lubricate “O” ring with coolant before installing. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Fill cooling system.

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2000-01 THERMOSTAT 5.4L V8 – VIN L

Removal
1. Partially drain the cooling system. Disconnect the upper radiator hose. Remove the 2 thermostat housing
bolts. Remove the thermostat housing. See Fig. 14 .
2. Remove the thermostat and the “O” ring seal. See . Discard the “O” ring seal.

Installation
1. Use a new “O” ring seal to position the thermostat in the upper intake manifold. Install the thermostat
housing and the bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect the
upper radiator hose. Fill and the cooling system.
2. Start the engine and allow to idle until normal operating temperature is reached. The engine coolant
temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the
upper radiator hose should feel hot to the touch. Shut the engine off and allow it to cool. Check the engine
for coolant leaks. Check the engine coolant level and fill as necessary.

01. July 2018 by sam
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2000-01 CAMSHAFT 5.4L V8 – VIN L

Removal
Remove camshaft followers and lash adjusters. See CAMSHAFT FOLLOWER & LASH ADJUSTER .
Remove timing chains. See TIMING CHAINS . Remove camshaft cap bolts in reverse order of tightening
sequence. See Fig. 13 . Remove camshaft caps and camshaft.

Inspection
Measure camshaft bore I.D. and journal O.D. to determine oil clearance. Measure lobe lift. Replace camshaft if
measurements are not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

Installation
1. Coat components with engine oil, and install components. Install all bolts for camshaft caps, and tighten
them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. See Fig. 13 .
2. Ensure camshaft end play is within specification. See CAMSHAFT table under ENGINE
SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to
specification. See TORQUE SPECIFICATIONS .

01. July 2018 by sam
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2000-01 CAMSHAFT FOLLOWER & LASH ADJUSTER 5.4L V8 – VIN L

Removal
1. Remove valve covers. See VALVE COVERS . Rotate crankshaft until piston in cylinder to be serviced
is at bottom of its stroke, and camshaft lobe is at base circle.
2. Install valve spring spacer between valve spring coils to prevent valve stem oil seal damage. Using valve
spring compressor, compress valve spring. Remove camshaft follower and lash adjuster.

Inspection
Inspect components for damage. Specifications are unavailable from manufacturer.

Installation
1. To install, reverse removal procedure. Coat components with engine oil before installing. Before
installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.
2. When installing fuel lines, fit NEW fuel resistant “O” rings (Brown) on fuel lines. Lightly coat “O” rings
with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

01. July 2018 by sam
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2000-01 TIMING CHAINS 5.4L V8 – VIN L

Removal
1. Remove front cover. See FRONT COVER . Remove crankshaft position sensor pulse wheel from
crankshaft. Using crankshaft positioner, position crankshaft as shown in illustration. See Fig. 8 . Install
camshaft holder, one on each cylinder head.
2. Remove right and left timing chain tensioners. Remove timing chain tensioner guides. Remove crankshaft
positioner. Remove right and left timing chains and crankshaft sprockets. Remove timing chain guides.

Inspection
Inspect components for damage. Inspect friction surfaces on tensioner arms and chain guides for wear. Replace
components if necessary. If tensioner arms or guides are worn or damaged, remove and clean oil pan. Also,
replace oil pump screen cover and tube.

Installation
1. Using edge of a vise, compress tensioner plunger. Using a small screwdriver, release ratchet mechanism
and retract ratchet arm. While holding ratchet arm in, install paper clip to hold ratchet assembly and
plunger in place during installation. See Fig. 9 .
2. If copper links are not visible, fold timing chain in half and mark 2 links on one end and one link on other
end of timing chains. See Fig. 10 . Install timing chain guides. Using crankshaft positioner, ensure that
crankshaft is aligned properly. See Fig. 8 .
3. Install right and left timing chains. Ensure timing marks and copper link are properly aligned. See Fig.
12 . Install timing chain tensioner guides. Install timing chain tensioners. Remove paper clip from timing
chain tensioners. Complete installation by reversing removal procedure. Tighten all nuts and bolt to
specification. See TORQUE SPECIFICATIONS .

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2000-01 FRONT COVER 5.4L V8 – VIN L

Removal
1. Disconnect negative battery cable(s). Remove valve covers. See VALVE COVERS . Remove radiator.
Remove water pump. See WATER PUMP . Raise and support vehicle. Remove power steering pump
retaining bolts, and position aside. Disconnect crankshaft position sensor harness connector. Drain engine
oil. Remove oil pan-to-front cover bolts.
2. Lower vehicle. Remove front oil seal. See FRONT CRANKSHAFT SEAL . Disconnect camshaft
position sensor harness connector. Remove accessory drive belt. Remove left side accessory drive belt
idler pulley. Remove front cover retaining bolts. Remove front cover and gasket.

Installation
To install, reverse removal procedure. Apply sealant at front cover-to-oil pan, cylinder block and valve cover
areas. Apply silicone sealant to keyway of crankshaft damper before installing. Tighten bolts to specification in
sequence. See Fig. 7 . See TORQUE SPECIFICATIONS .

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2000-01 FRONT CRANKSHAFT SEAL 5.4L V8 – VIN L

Removal
Disconnect negative battery cable(s). Remove crankshaft pulley. Using front cover seal remover, remove front
seal.

Installation
Lubricate oil seal bore and seal lip with engine oil before installing. Using seal installer, install oil seal. Apply
silicone sealant to keyway of crankshaft damper before installing. Using crankshaft damper replacer, install
crankshaft damper. To complete installation, reverse removal procedure. Tighten bolts to specification. See
TORQUE SPECIFICATIONS

01. July 2018 by sam
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