Ford Falcon. Manual — part 132

303-01b-42

Engine — 5.4L (3V)

303-01b-42

IN-VEHICLE REPAIR (Continued)

3. 3. Remove the oil level indicator tube.

2. Install the special tool.

a. Install a new O-ring seal.

3. Raise and support the vehicle. For additional

information, refer to Section 100-02.

Installation

Install in the reverse order to the removal.

4. Remove through bolts from the engine mount

bracket and chassis.

Oil Pan

5. Drain the engine oil.

Special Tool(s)

3-Bar Engine Support 303-F073

Materials
Metal Surface Cleaner

WSE-M5B392-A

F4AZ-19A536-RA or

equivalent
Silicone Gasket and

WSE-M4G323-A4

6. Lower the vehicle.

Sealant

7. Raise the engine 63.5 mm.

F7AZ-19554-EA or

LOCTITE 5900 or

equivalent
10W-30 GF2 Engine Oil

WSS-M2C910-A2

or equivalent

Removal
1. Remove alternator, refer to Section 414-02.

8. Raise

the

vehicle

G89785 en

303-01b-43

Engine — 5.4L (3V)

303-01b-43

IN-VEHICLE REPAIR (Continued)

9. Remove the bolts, oil pan and gasket.

3. Apply silicone gasket and sealant at the front

cover-to-cylinder block sealing surface.

Inspect the oil pan gasket for damage.

NOTE: If the oil pan and the oil pan gasket are

NOTE: Be careful when removing oil pan

not secured within four minutes, the sealant must

gasket. It is re-usable if not damaged.

be removed and the sealing area cleaned with

metal surface cleaner. Allow to dry until there is

no sign of wetness, or four minutes, whichever is

longer. Failure to follow this procedure can cause

future oil leakage.

Installation
1. Clean the mating surfaces.

CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or other

4. Install the oil pan gasket and the oil pan and

abrasive means to clean the sealing surfaces.

loosely install the 16 bolts.

These tools cause scratches and gouges

5. Tighten the bolts in three stages, in the sequence

which make leak paths. Use a plastic scraping

shown.

tool to remove all traces of old sealant

Stage 1: Tighten to 2 Nm.

2. Apply silicone gasket and sealant at the rear oil

seal retainer-to-cylinder block sealing surface.

Stage 2: Tighten to 20 Nm.

NOTE: If the oil pan and the oil pan gasket are

not secured within four minutes, the sealant must

be removed and the sealing area cleaned with

metal surface cleaner. Allow to dry until there is

no sign of wetness, or four minutes, whichever is

longer. Failure to follow this procedure can cause

future oil leakage.

Stage 3: Tighten an additional 60 degrees

6. Lower the vehicle.

G89786 en

303-01b-44

Engine — 5.4L (3V)

303-01b-44

IN-VEHICLE REPAIR (Continued)

7. Lower the engine.

Removal

Remove the special tool.

1. Remove the oil pan. For additional information,

refer to Oil Pan in this section

2. Remove the three (A) bolts and the (B) oil pump

screen cover and tube.

8. Raise

the

vehicle.

9. Install through bolt to the engine mount bracket

and chassis.

Installation
1. Clean and inspect the mating surfaces.

Inspect the O-ring seal

2. Install the oil pump screen cover and tube and

install the bolts.

CAUTION: Make sure the O-ring is in

place and not damaged. A missing or

damaged O-ring can cause foam in the

lubrication system, low oil pressure and

severe engine damage.
NOTE: Clean and inspect the mating surfaces

and install a new O-ring. Lubricate with clean

engine oil.

10. Lower the vehicle.

3. Install the oil pan. For additional information, refer

11. Install the alternator. For additional information,

to Oil Pan Installation in this section.

refer to Section 414-02.

Flywheel

12. Install the lower intake manifold. For additional

information, refer to Intake Manifold-Upper.

Removal

13. Refill the engine crankcase with clean engine oil.

1. Remove the transmission. For additional

information, refer to Automatic Transmission

Oil Pump Screen and Pickup Tube

chapter 307-01 or for Manual Transmission

chapter 308-03B.

Materials

2. Remove the clutch disc and pressure plate.

10W-30 GF2 engine oil

WSS-M2C910-A2

Manual transmission only. For additional

or equivalent

information, refer to Clutch chapter 308-01

G89786 en

303-01b-45

Engine — 5.4L (3V)

303-01b-45

IN-VEHICLE REPAIR (Continued)

3. Remove six of the eight bolts. Loosen the two

Crankshaft Rear Oil Seal

remaining bolts but leave in place.

Special Tool(s)

CAUTION: Two bolts should be loosened

but left in to prevent the flywheel (6375) from

Installer, Crankshaft Rear Oil

falling

Seal 303-518 (T95P-6701-DH)

Remover, Crankshaft Rear Oil

Seal 303-519 (T95P-6701-EH)

Installer, Crankshaft Rear Oil

Seal 303-516 (T95P-6701-BH)

4. Separate the flywheel from the crankshaft
5. Remove the bolts remaining in the crankshaft.
6. Remove the flywheel.
Installation
1. Position the flywheel onto the crankshaft and

install the flywheel-to-crankshaft bolts (6379).

Remover, Crankshaft Rear Oil

Apply the threadlock and sealer to bolt

Slinger 303-514

threads.

(T95P-6701-AH)

Installer, Crankshaft Rear Oil

Slinger 303-517

(T95P-6701-CH)

Impact Slide Hammer 100-001

(T50T-100-A)

2. Install the disc and pressure plate. Manual

transmission only. For additional information, refer

to Clutch chapter 308-01

3. Install the transmission. Refer to Automatic

Transmission chapter 307-01 or for Manual

Transmission chapter 308-03B.

Removal
1. Remove the Flywheel. For additional information,

refer to Flywheel in this section.

G89788 en