engine swap

ddabb · #1 (**permalink**) 10-22-2009, 01:11 AM

I need to replace my 4.6 in my 2003 expy. Will a 2002 fit? Or will a 2003 5.4 fit?

ford12508 · #2 (**permalink**) 10-22-2009, 06:14 AM

A 2002 will not fit because they are 2 different engine, and a 5.4 could fit, but you will have to make other adjustments. your best bet is just to get a jasper 4.6L or one from a totalled car that was t-boned or something like that where the engine wasnt hit.

benningstspeed1.0 · #3 (**permalink**) 10-22-2009, 07:57 AM

a 2002 might fit. the engine is the same, but you have to watch out for windsor or romeo engines. you also have to watch for the front covers and valve covers so that all of the actaching locations are the same. a 5.4l will fit but like stated before there will be things that will need to be changed. the only way to do a in and out swap is to get an engine just like yours

Johnny Langton · #4 (**permalink**) 10-22-2009, 08:13 AM

Quote:

Originally Posted by ddabb

I need to replace my 4.6 in my 2003 expy. Will a 2002 fit? Or will a 2003 5.4 fit?

ALL 4.6L iron blocks are the same externally.
The differences between Romeo and Windsor are minor-the only one that'll cause you problems is the number of flexplate to crankshaft bolts. Windsors use 8,and the Romeos use 6. This is really a non-issue,all 4.6L's are internally balanced,so all you need is a flexplate with the correct number of crankshaft bolt holes.If you end up with a different year model,I'd suggest using the top end (induction,etc) from your original engine to help prevent any hassles with senor locations being slightly different,and problems with the harness.
A 5.4L would fit fine-you'll just have to alter the exhaust and the PCM will need a custom tune to be perfect. It'll run off of the 4.6L PCM, but it won't be optimal.
JL

benningstspeed1.0 · #5 (**permalink**) 10-22-2009, 09:52 AM

Different years of 4.6l can have differnet valve covers(number of bolts) and differnet front covers(accessory location). We have changed out many engines and have had to change parts to make it work.

Johnny Langton · #6 (**permalink**) 10-22-2009, 10:04 AM

Quote:

Originally Posted by benningstspeed1.0

Different years of 4.6l can have differnet valve covers(number of bolts) and differnet front covers(accessory location). We have changed out many engines and have had to change parts to make it work.

Cam cover differences are simply Windsor vs Romeo. That means nothing to this swap application. The front cover may need to be swapped-just depends on what donor vehicle he's gonna get the engine from.
JL