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Need help finishing up an engine install

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Old Sep 23, 2019 | 06:27 PM
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Default Need help finishing up an engine install

2003 XLT supercab 5.4L 2WD

First post since my google and forum searching is going no where so hoping i can get a bit of help.
This is my first time dealing with a newer (OBD 2) motor; mostly worked on older jeeps.
Assuming I have not messed up any of the lines the two below are the last ones i need (1) is coming from the firewall (2) is coming off the cluster of lines coming from the valve cover
Number 3 is the only electrical connection i cant seem to find a connection for either.
So any info on what I'm missing would be great apart from these three things I am waiting on the transmission cooling lines to be delivered and putting in a battery and filling up fluids and should be ready to start it and then get body parts back on.

More pics of original engine and associated issues are in my gallery on the site it jumped timing and put a hole on the driver side of the block. Donor motor is from same year expedition but i have used as much of the lines and parts from the original truck as possible.
Thanks in advance for any help as the site saved me a few different times on doing timing chains and a few vacuum hose connection sorting problems.
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Old Sep 23, 2019 | 09:33 PM
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2003, 5.4? Is that what the truck started with? Is this what's going in to the truck? Is the original engine going back in after being out? Just saving someone else from asking all of this but a full description of what you've got going on with your install would be helpful.

Your pictures are limited in what they show. On my truck, the hoses and tubes at the passenger side of the firewall (right side) are to the heater and AC.

Last edited by River1; Sep 23, 2019 at 09:37 PM.
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Old Sep 23, 2019 | 09:57 PM
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1 - Heater core hardline connect. (behind the pass side head).

2 - AC drain tube. (Also behind pass side head and a big PITA to connect w/engine in)

3 - RFI capacitor. (Its in the shape of a square/ connects to any fastener used on a metal part. Commonly found around the front of the engine, just one red wire connect)
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Old Sep 23, 2019 | 10:07 PM
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I was kind of wordy with the last paragraph sorry

Originally Posted by River1
2003, 5.4? Is that what the truck started with? Yes original block was a SOHC 5.4L Triton that now has a hole in it Is this what's going in to the truck? No donor motor i was told was a 5.4L out of 2003 expedition. Is the original engine going back in after being out? the block and heads from the expedition were used with the
Motor mounts, timing cover (needed as expedition power steering pump was different and the F150 mounting holes were on the timing cover) and all accessories (tensioner, idler pulleys, AC, PS) intake, fuel rail, and valve covers are all from the original blown motor that was pulled from the truck.

Just saving someone else from asking all of this but a full description of what you've got going on with your install would be helpful. Brief run-down original 5.4 had hole in block, donor motor with external parts from the original are back in the truck and nearly all parts have matched up except the three things in the photo. tube labeled number 1 is from the firewall and never was removed from the truck the electrical connection was from the original wiring harness that was not removed from the truck. Tube 2 could have been a mess up on my part and be from the expedition and an extra line that is not on the f150 as it was a part not left attached to the truck.

Your pictures are limited in what they show. On my truck, the hoses and tubes at the passenger side of the firewall (right side) are to the heater and AC. I agree it was the best pic I could get of them all together was trying not to flood the post with photos but I will grab a few better ones tomorrow in the daylight.
Hope that helps sort out the first post and I will try to get clear individual picks of the tubes in the morning and post them.
This is how the truck is currently sitting after finishing up yesterday with what I could;
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Old Sep 23, 2019 | 10:21 PM
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Originally Posted by Jbrew
1 - Heater core hardline connect. (behind the pass side head).

2 - AC drain tube. (Also behind pass side head and a big PITA to connect w/engine in)

3 - RFI capacitor. (Its in the shape of a square/ connects to any fastener used on a metal part. Commonly found around the front of the engine, just one red wire connect)
Thank you! Looked up the RFI and it mounts on the stud on the timing cover thats empty on my truck, looked at photos from before i tore the old motor out and it was never there so I will have to order one or hunt it down at a JY. the two tubes on the other hand, I guess its back on the search or i messed up and connected a different tube to something because looking I didn't see an open spot anywhere before I ran out of light and gave up and came in to search google photos. Now you have me excited if I just overlooked the connections it is just waiting on the two transmission cooling lines to come in from being ordered and I can see if it will start or if i messed up something up! (Fingers Crossed).
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Old Sep 24, 2019 | 09:56 AM
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Is everything 03 with this swap ? I see you used an Expy engine. Okay, the Expy or the manifold your using is set up for the cold climate system. If both manifolds and throttle body elbows are set up the same....shouldn't have a problem.

Anyway, you have to behind the passenger side head for the heater core pipe, - it's black and connected to the water pump ends behind the head/cam cover. That's were you connect the fat hose coming from the core itself.

The AC drain hose. I'm not totally sure it's AC, it looks to be coming from the AC port on the FW.. IF that's the case, all you have to do is rout it to the side of the trans to direct drainage. HOWEVER, the hose itself looks just like a heater core bypass hose which connects in the same area. If it's a bypass hose it will connect to the same heater core hard line that the other hose does...just further downstream (like say an inch or two) to it's own T connection.

You might have to move the engine harness out of the way to locate the tube port connections behind the head.

Also, you need to pin down cruise and throttle cables to the power steering reservoir flange. Something doesn't look right with the upper radiator hose...maybe it's just the support.

Make sure you get those hoses connected before filling with coolant lol.

Last edited by Jbrew; Sep 24, 2019 at 11:50 AM.
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Old Sep 24, 2019 | 02:52 PM
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Originally Posted by Jbrew
1 - Heater core hardline connect. (behind the pass side head).

2 - AC drain tube. (Also behind pass side head and a big PITA to connect w/engine in)

3 - RFI capacitor. (Its in the shape of a square/ connects to any fastener used on a metal part. Commonly found around the front of the engine, just one red wire connect)
Got out to look this morning and 1 and 3 were dead on and are now taken care of. The one you labeled being from the AC drain is all that's left so thank you for the help so far. That last line is coming off the PCV i got a better picture of where it is running from i need to remove the kinked up boot and straighten it out as well.



Your warning about that that heater hose was no joke it wasn't bad getting the tube itself on but getting the hose clamp on was a royal pain but its in place. On my way to order the resistor as well. I haven't added any fluids didn't want to until i was sure everything was in place so close now thanks to your help.
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Old Sep 24, 2019 | 03:21 PM
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That PCV valve does not appear to be a Motorcraft. If it is not, seriously discard it and get a Motorcraft. Aftermarket PCV valves wreak havoc on these modular motors.
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Old Sep 24, 2019 | 03:46 PM
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Originally Posted by white89gt
That PCV valve does not appear to be a Motorcraft. If it is not, seriously discard it and get a Motorcraft. Aftermarket PCV valves wreak havoc on these modular motors.
This tag came on my 5.4 reman from Ford that was put in last month. It pretty much says it all.
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Old Sep 24, 2019 | 04:42 PM
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Originally Posted by white89gt
That PCV valve does not appear to be a Motorcraft. If it is not, seriously discard it and get a Motorcraft. Aftermarket PCV valves wreak havoc on these modular motors.
I will get on that then as well, bonus point figuring out which one I need I figured out that that and the other line are for coolant jacket around it. Also that it goes on a nipple that is farther down the pain in the *** tube the heater return hose went on, so all my mystery connections are figured out. So thanks everyone for the help, got to sort out these two transmission lines, a new pcv and the little plastic check valve up by the break booster then fill up all the fluids. Hopefully can post up when it is up and running in a day or so if parts get here quick.
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