I pulled the 5.4 out of my '99 Expy a few weeks ago. When I pulled it out, I had already removed the intake and heads. I had to remove the whole front bumper/grille to get the engine hoist close enough to pull the engine. I am ready to put the engine back in and my question is how much of the engine to assemble before putting it back in? Ideally, I would like to pre-assemble Oil pan, heads (with exhaust manifolds), intake (without the throttle body), and valve covers but I don't know if all of that will go back in together. My second choice would be the same except to mount the oil pickup tube and oil pan after the engine is in the engine bay but before I set the engine down onto the engine mounts. I have some pics of the engine bay.

I wasn't sure which is the best forum for this question. I also posted it in the Expedition & Navigator forum. My apologies if the double post is a bad thing! Thanks for your help!

 

Assemble it to a long block(heads, valve covers, timing cover, oil pan, exhaust manifolds) and it will go in. It helps to loosen the trans mount and slide the trans back as far as it will go. Don't try to line up the bellhousing and torque converter from the top, I have found it's easier to set the engine in close and line everything up under the truck. Cut the heads off 2 long metric bolts and thread into the block on either side to use as guide pins for the bellhousing bolts. Once the bellhousing is aligned then align the torque converter studs to the flywheel. Don't use the bellhousing bolts to draw the trans to the engine, you should be able to pry it forward at the trans mount. The torque converter should be able to wiggle back and forth a little with the trans tight against the engine.

 

Great information! Thanks!

So leave the intake and throttle body off and put them on once the engine is mounted?

 

yep it wont fit with the intake on

 

Ok. I appreciate your help! I'll update the thread and let you know how it goes!

 

When I'm putting the engine back in...Are there any alignment "issues" between the engine/flywheel and the trans/torque converter? In other words...other than lining up the bolt/bolt holes, does the flywheel or trans/torque converter need to be in any certain position in relation to each other? Thanks!

 

The studs on the torque converter need to go into the holes on the flywheel. That's why I said to loosen the trans mount and slide it back as far as it will go. That will give you the room needed to set the engine in the mounts and then line up the trans and torque converter from underneath.

 

Woohoo!! I got it in today! I did what you said and it worked great!! But, we knew that would happen, right? Lol! Thanks so much for your help! Now I've got to get everything hooked back up!

BTW, I want to flush my heater cores before I hook everything up. I have rear air/heat. Which tubes are the inlets and which are the outlets on the heater cores?

 

I'm glad you got it in The inlet for the heater is the hose that hooks up at the front of the intake on the coolant crossover tube and the outlet is the hose that hooks up the the metal tube that is bolted to the right cyl head and runs under the intake to behind the water pump.

 

Speaking of the metal tube that runs under the intake...I replaced the 2 O-rings where it connects to the block at the back of the water pump. Do I need to put any sealant or RTV on there, or the O-rings enough?

 

The o-rings will be good enough.

 

Ok. Thank you for all your help!