Ford Falcon. Manual - part 135

303-01b-54 

Engine — 5.4L (3V) 

303-01b-54

IN-VEHICLE REPAIR (Continued)

23. Position the power steering pump and install the

34. Connect the transmission wiring harness to

bolts.

transmission.

24. Connect the power steering pressure sensor.

35. Connect wiring harness (PCM ’A’ connector and

24 pin connector) to vehicle.

25.  Lower the vehicle.

36. Install the alternator and alternator bracket.

26. Connect the lower radiator hose.
27. Install the stud and reposition the A/C muffler.
28.  Install battery into vehicle.
29. Connect the heater hoses to rear of engine.

37. Connect the alternator electrical connectors.

30. Install surge tank into vehicle.
31. Connect vent and supply hoses to surge tank.
32. Connect the surge tank return hose.
33. Install the two bolts retaining the transmission to

the engine.

38.  Connect battery and alternator cables to RH relay

box.

39. Install the accessory drive belt. For additional

information, refer to Section 303-05.

40. Install the intake manifold. For additional

information, refer to Intake Manifold-Upper in this

section.

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303-01b-55 

Engine — 5.4L (3V) 

303-01b-55

IN-VEHICLE REPAIR (Continued)

41. Install the radiator.

Install the radiator mounting insulators.
Position the radiator on the radiator mounting

insulators.
Position the brackets.
Install the bolts.

45. Install the fan shroud.

Install the fan blade and fan shroud, as a unit,

in the vehicle.
Install the screws.

42. Install the surge tank hose to the radiator.

Release the clamp.
Slide the hose onto the radiator fitting.

46. Recharge the A/C system. For additional

information, refer to Section 412-00.

47. Fill the engine with oil.
48. Fill the engine cooling system. For additional

information, refer to Section 303-03.

43. Connect the lower radiator hose and the upper

radiator hose.

44. Connect the transmission fluid cooler fittings.

Connect the lower transmission fluid cooler

fitting.
Connect the upper transmission fluid cooler

fitting.
NOTE: To avoid disturbing the transmission

oil cooler fittings, use a support hammer when

tightening fuel lines.

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303-01b-56 

Engine — 5.4L (3V) 

303-01b-56

DISASSEMBLY

Disassembly

Engine

NOTE: The crankshaft rear oil seal, the oil seal slinger

and the oil seal retainer plate must be removed before

Special Tool(s)

mounting the engine on the engine stand.

Remover, Crankshaft Rear Oil

1.  Remove the bolts and the flexplate or the

Slinger

flywheel.

303-514 (T95P-6701-AH)

Remover, Crankshaft Rear Oil

Seal

303-519 (T95P-6701-EH)

Slide Hammer

100-001 (T50T-100-A)

2.  Using the special tools, remove the crankshaft

rear oil slinger.

Installer, Connecting Rod

303-442 (T93P-6136-A)

Lift Bracket Set, Engine

303-DS086 (D93P-6001-A)

3.  Using the special tools, remove the crankshaft

rear oil seal.

Remover, Crankshaft Vibration

Damper

303-009 (T58P-6316-D)

Remover, Crankshaft Front Oil

Seal

303-107 (T74P-6700-A)

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303-01b-57 

Engine — 5.4L (3V) 

303-01b-57

DISASSEMBLY (Continued)

9.  Remove the intake manifold gaskets.

4.  Remove the bolts, oil pan and oil pan gasket.

Clean and inspect the sealing surfaces.

Clean and inspect the sealing surfaces.

 CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or

other abrasive means to clean the sealing

surfaces. These tools cause scratches and

gouges which make leak paths. Use a

plastic scraping tool to remove all traces

of old sealant.

5.  Remove the bolts and the crankshaft rear oil seal

retainer plate.

Clean and inspect the sealing surfaces.

10. Remove the bolts and the generator support

bracket.

6.  Install the engine onto a suitable engine stand.
7.  With the engine on the engine stand, remove the

engine control sensor wiring harness.

8.  Remove the bolts and the intake manifold

assembly.

11. Remove the bolts and the generator.

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