2000-01 VALVE COVERS 5.4L V8 – VIN L

Removal (Expedition, Navigator & Pickup – Left)
1. Disconnect negative battery cable(s). Remove air cleaner. Unbolt power steering reservoir bracket, and
position reservoir and bracket assembly aside.
2. Disconnect PCV hose from valve cover. Disconnect control cables from throttle body. Unbolt throttle
body control cable bracket, and position aside. Remove EGR manifold tube. Disconnect necessary
harness connectors. Remove valve cover retaining bolts. Remove valve cover and gasket.
Removal (Expedition, Navigator & Pickup – Right)
1. Disconnect negative battery cable(s). Remove air cleaner. Disconnect PCV valve hose from valve cover.
Remove throttle body splash shield. Remove junction block splash shield.
2. Remove junction block cables from starter relay. Unclip mega fuses from junction block bracket.
Disconnect necessary harness connectors. Remove junction block bracket. Remove heater hoses.
Disconnect emissions vacuum control connections. Disconnect crankshaft position sensor electrical
connection. Remove valve cover and gasket. Valve cover bolts are part of valve cover and should not be
removed.

Removal (Van)
Disconnect negative battery cable(s). Remove engine cover. If removing left valve cover, remove air cleaner
and outlet tube. Remove EGR manifold tube. If removing right valve cover, remove oil filler tube. If removing
either valve cover, remove PCV tube from valve cover. Disconnect necessary harness connectors. Remove
valve cover and gasket. Valve cover bolts are part of valve cover and should not be removed.

Installation (All Models)
1. Clean sealing surfaces on valve cover and cylinder head. Using gasket adhesive, glue valve cover gasket
to valve cover. Apply a bead of silicone gasket adhesive to seam where cylinder head and front cover
meet.
2. Install valve cover, and tighten retaining bolts in sequence. See Fig. 6 . To complete installation, reverse
removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .
3. 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 CYLINDER HEAD 5.4L V8 – VIN L

Removal
1. Remove the engine. See ENGINE . Remove the flexplate or flywheel. Mount the engine on a suitable
work stand. Remove exhaust manifold. See EXHAUST MANIFOLD .
2. Remove timing chains. See TIMING CHAINS . Remove cylinder head bolts in reverse order of tightening sequence. See Fig. 5 . Remove cylinder head and gasket.

Inspection
Check cylinder head for warpage, cracks and damage. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS. Repair or replace cylinder head as necessary.

Installation
1. Ensure proper gaskets are installed. Right and left cylinder head gaskets are not interchangeable. Install
crankshaft holder. Install camshaft holder, one on each head.
2. Install cylinder heads and retaining bolts. Torque bolts in sequence and to specification. See Fig. 5 . See
TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Tighten nuts and
bolts to specification.

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

Removal
Raise and support vehicle. Remove front fender splash shield. Remove wheel opening molding on 4WD
models. If removing left exhaust manifold, remove EGR manifold tube and brake vacuum booster hose bracket.
On either side, disconnect exhaust manifold flange. Remove exhaust manifold retaining nuts in reverse order of
tightening sequence. See Fig. 4 . Remove exhaust manifold and gasket.

Installation
To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. See Fig. 4 .
See TORQUE SPECIFICATIONS .

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

Removal
1. Disconnect negative battery cable(s). On vans, remove engine cover. On all models, release fuel pressure
and disconnect fuel lines. See FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS .
2. Drain cooling system. Disconnect upper radiator hose from thermostat housing. Remove air cleaner and
outlet tube assembly. Disconnect control cables from throttle body. Unbolt throttle body control cable
bracket and position aside.
3. Disconnect necessary vacuum and water connections. Disconnect necessary harness and ground
connections. Remove brake booster vacuum hose bracket. Remove EGR manifold tube. Remove spark
plug wires. Remove accessory drive belt. Remove generator.
4. Remove throttle body. Remove heater return tube. Remove thermostat. Remove upper intake manifold
retaining bolts in reverse order of tightening sequence. See Fig. 2 . Lift intake manifold assembly,
disconnect manifold turning valve and remove intake manifold assembly from vehicle.
5. If separating upper and lower intake manifolds, remove lower intake manifold retaining bolts in reverse
order of tightening sequence. See Fig. 3 . Separate intake manifolds, and remove gasket.

Installation
1. To install, reverse removal procedure. Use NEW gaskets and “O” rings. Tighten intake manifold bolts to
specification in sequence. See Fig. 2 and Fig. 3 . See TORQUE SPECIFICATIONS .
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).
3. To install remaining components, reverse removal procedure. Adjust all control cables and fluid levels.
Refill cooling system. When installing spark plug wires, ensure wires are in correct position on coils.

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

Removal (Expedition, Navigator & Pickup)
1. Disconnect negative battery cable. Remove hood. Remove air cleaner assembly. Remove accessory drive
belt. Drain cooling system. Remove radiator. Discharge A/C system using approved refrigerant
recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE
RELEASE & FUEL LINE CONNECTIONS .
2. Disconnect necessary harness and ground connections. Disconnect necessary water and vacuum
connections. Remove A/C condenser, and plug openings. Remove EGR manifold tube, and unclip mega
fuse holders from junction block bracket. Remove junction block bracket.
3. Remove intake manifold. See INTAKE MANIFOLD . Remove bulkhead connector cover. Unbolt
power steering bracket, and position reservoir and bracket assembly aside.
4. Raise and support vehicle. Remove starter. Remove A/C compressor, and plug openings. Remove
transmission cooler line from block mounted clip. Remove transmission inspection cover, torque
converter bolts and transmission-to engine bolts. Remove power steering retaining bolts, and position
power steering pump aside.
5. Disconnect dual-converter “Y” pipe from exhaust manifolds, and position aside. Remove right and left
engine mount bolts. Remove oil cooler, and position oil cooler aside. Remove oil filter adapter. Lower
vehicle and support transmission. Remove engine from vehicle.

Installation
1. To install, reverse removal procedure. Tighten all bolts to specification. See TORQUE
SPECIFICATIONS .
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).
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and charge A/C system.

Removal (Van)
1. Disconnect negative battery cable(s). Discharge A/C system using approved refrigerant
recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See FUEL PRESSURE
RELEASE & FUEL LINE CONNECTIONS .
2. Disconnect necessary harness and ground connections. Remove intake manifold. See INTAKE
MANIFOLD . Remove air deflector, radiator grille, radiator grille opening panel and upper and lower
core supports. Remove radiator, fan shroud and cooling fan.
3. Remove headlight and side marker assemblies. Remove A/C condenser, and plug openings. Remove
accessory drive belt. Drain power steering fluid by disconnecting reservoir hose at power steering pump.
Disconnect high pressure hose at power steering pump. Remove lower radiator hose. Disconnect suction
hose at receiver-drier, and plug openings.
4. Raise and support vehicle. Disconnect dual-converter “Y” pipe at exhaust manifold. Drain engine oil and
remove oil filter. Remove oil cooler. Remove starter. Remove transmission-to-engine bolts.
5. Remove and discard torque converter nuts. Remove engine mount-to-subframe nuts. Lower vehicle.
Remove transmission oil filler tube. Support transmission. Remove engine from vehicle.

Installation
1. To install, reverse removal procedure. Replace torque converter nuts with NEW ones. Tighten all bolts to
specification. See TORQUE SPECIFICATIONS .
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).
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and charge A/C system.

01. July 2018 by sam
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2000-01 FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS 5.4L V8 – VIN L

1. Remove fuel cap to release fuel tank pressure. Connect EFI Pressure Gauge to relief valve on right rear corner of fuel rail. Release pressure using valve on pressure gauge.
2. Before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
3. Install Spring Lock Coupling Remover (D87L-9280-A for 3/8″ line; D87L-9280-B for 1/2″ line) on fuel line coupling so it enters cage opening. See Fig. 1 .
4. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
5. When installing fuel lines, fit NEW fuel resistant “O” rings (Brown) on fuel lines. Before installing, lightly coat “O” rings with clean engine oil. Clean fittings, and replace garter spring (if necessary).
6. Install female fitting to male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines lock together and garter spring is over female fitting flared end.
7. Install retaining clip. Install Black retaining clip on fuel supply line and Gray clip on fuel return line. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

01. July 2018 by sam
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2000-01 OIL PUMP 4.6L V8 – VIN W & 6

Removal
Remove oil pan and pick-up tube. See OIL PAN under REMOVAL & INSTALLATION. Remove timing chains and crankshaft sprockets. See TIMING CHAINS under REMOVAL & INSTALLATION. Remove retaining bolts, and remove oil pump.

Installation
To install, reverse removal procedure. Ensure flat areas of oil pump rotor aligns with flat areas of crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS

01. July 2018 by sam
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2000-01 ENGINE LUBRICATION SYSTEM 4.6L V8 – VIN W & 6

Rotor-type pump is driven by crankshaft and delivers pressurized oil to main gallery.

Crankcase Capacity
On vehicles with automatic transmissions, crankcase capacity is 6.7 qts. (6.3L). With manual transmissions, crankcase capacity is 6.5 qts. (6.1L).

Oil Pressure
With engine at normal operating temperature, normal oil pressure is 20-45 psi (1.4-3.2 kg/cm 2 ) at 1500 RPM.

01. July 2018 by sam
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2000-01 CYLINDER BLOCK ASSEMBLY 4.6L V8 – VIN W & 6

Piston & Rod Assembly
Note direction of connecting rod installation on piston. Install piston and connecting rod in engine, with notch on top of piston toward front of engine. See Fig. 20 or Fig. 21 .

Fitting Pistons
1. Standard service pistons are color-coded Red, Blue or Yellow 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 1/2″ below top of piston travel and 1/2″ 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 notch on top of piston toward front of engine. See Fig. 20 or Fig. 21 .
2. Check bearing clearances using Plastigage method. 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 .010″ (.25 mm) undersize bearings. Tighten connecting rod bearing cap bolts to specification. See TORQUE SPECIFICATIONS .

Crankshaft & Main Bearings
1. Measure main bearing clearances using Plastigage method. 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 cap rearward (DO NOT COCK). Tighten main bearing cap bolts to specification in 2 steps using proper sequence. See Fig. Fig. 24 or Fig. 25 . See TORQUE SPECIFICATIONS .
4. Tighten side adjusting screws against cylinder block to specification in 2 steps using proper sequence. See Fig. 24 or Fig. 25 . 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 1/2″ below top of
cylinder block head surface and 1/2″ 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 4.6L V8 – VIN W & 6

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 (T91T-6571-A) 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 bored out and replaced with a service 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 60-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).

01. July 2018 by sam
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