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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