Engine swap

[Bowesmobile]

I'm going to be swapping my 4.6L from my 1997 for a good running 4.6L from a '99. I will try and document as much as I can for posterity and maybe be able to help someone out in the future.

 

[98EXPnSRQ]

Cool, thanks and good luck. The 99 has the PI heads, right?

 

[Bowesmobile]

I'm getting mixed results on that. The motor is out of a 1999 F150. Now some say no they didn't get the PI heads and intake until 2001. Others say it was late model 1998 builds and on that got it. Then others say yes all 1999 F150's have it. I'm going to check the heads and see if its written on them . PI heads have "PI" cast into them over the front exhaust port. So I will see. Either way its better than a motor running on 7 1/2 cylinders. Plus it only cost me $500 for a complete running motor with a 30 day warranty.

 

[98EXPnSRQ]

This is a good read

Increasing Power Output - 4.6L Modular Ford Motor - Sport Truck Magazine

 

[01yellerCobra]

You just need to look at the intake ports. The PI ports are noticeably bigger and shaped different than NPI intake ports.

 

[Bowesmobile]

This is a good read

Increasing Power Output - 4.6L Modular Ford Motor - Sport Truck Magazine

Nice read! Good to see it doesn't take much to make more power. I should pull the heads and port and polish the intake and exhaust.

 

[Bowesmobile]

It's a 1998 motor and a NPI. So I'm a little sad. But it's not going backwards it's just staying even. Here are some pictures of the motor.

[URL=http://s541.photobucket.com/user/bowesmobile/media/1415481363.jpg.html]
[URL=http://s541.photobucket.com/user/bowesmobile/media/1415481365.jpg.html]
[URL=http://s541.photobucket.com/user/bowesmobile/media/1415481375.jpg.html]

 

[Bowesmobile]

Tonight I pulled the intake, water pump, fuel rail and injectors. Cleaned out the valley under the intake. Pulled my expy into the car port and pulled the hood, intake tube and front cover. Tomorrow will be draining the fluids, pulling the intake on the old motor and breaking loose bolts.

 

[Yudaman]

After owning a '99 Expy with a 4.6, consider yourself lucky that the new motor is a '98.
Otherwise you would prolly get it installed just to find out a head gasket had blown.

Good luck with the swap and keep the updated coming!

 

[Bowesmobile]

Well, thats what the 30 day warranty is for. Although I will be pretty pissed.

 

[98EXPnSRQ]

I would be seriously temped to pull the heads and do some hand porting.

 

[Yudaman]

Another thing. While it is out and on the stand, I would change plugs and COPS. So much easier to do with room to work!

 

[Bowesmobile]

So after quite a few set backs I have some advise. You need a wrench like this if you want to remove the top two bolts from the trans to motor bolting. Tried to get a open end box end wrench in there and no luck. Bought this set from Harbor freight and had both bolts out in 10 minutes.

 

[BIG GREEN FORD]

So after quite a few set backs I have some advise. You need a wrench like this if you want to remove the top two bolts from the trans to motor bolting. Tried to get a open end box end wrench in there and no luck. Bought this set from Harbor freight and had both bolts out in 10 minutes.

I took mine off from the bottom of my old expy

 

[Bowesmobile]

I tried that as well. The heat shields for the cats were in the way. I couldn't get it to fit into place square on the bolt. The shallow well socket and swivel were too long and kept hitting the fire wall keeping it off square. Hey for $20 that socket set is the cats meow!

 

[Bowesmobile]

The motor is out. It can be difficult to pull. The intake has to come off. You need to have a load leveler. Mount it as close the to the intake mounting surface on the heads as you can. Lift the engine and separate it from the trans with a pry bar. Tilt the front of the engine slightly up to clear the motor mounts. As soon as you get the engine to clear the mounts, tilt it so the front of the engine is as straight up and down as you can get it. I didn't do this and my engine shifted forward, hitting the A/C condenser causing it to crack. So that will have to be repaired in the spring. Now its time to clean up the engine compartment and get ready for the new engine to go in.

 

[IMINYOURCHAIR]

Shoot me a pm when you're ready to do the ac.

 

[98EXPnSRQ]

The motor is out. It can be difficult to pull. The intake has to come off. You need to have a load leveler. Mount it as close the to the intake mounting surface on the heads as you can. Lift the engine and separate it from the trans with a pry bar. Tilt the front of the engine slightly up to clear the motor mounts. As soon as you get the engine to clear the mounts, tilt it so the front of the engine is as straight up and down as you can get it. I didn't do this and my engine shifted forward, hitting the A/C condenser causing it to crack. So that will have to be repaired in the spring. Now its time to clean up the engine compartment and get ready for the new engine to go in.

Did you use a cherry picker style engine hoist or an overhead hoist? Have any pics of it coming out?

 

[Bowesmobile]

I definitely will. I plan on going through everything so I can have ice cold air next summer.

 

[Bowesmobile]

Did you use a cherry picker style engine hoist or an overhead hoist? Have any pics of it coming out?

I used a cherry picker style. Sadly I was alone and didn't have the ability to take a picture while pulling it out.