Ford Falcon. Manual — part 124

303-01b-10

Engine — 5.4L (3V)

303-01b-10

IN-VEHICLE REPAIR (Continued)

Materials

15. Clean and inspect the sealing surfaces.

Metal Surface Prep

ZC-31

Silicone Gasket and

WSE-M4G323-A4

Sealant

F7AZ-19554-EA or

equivalent
Instant Adhesive

WSK-M2G402-A4

E8AZ-19554-A

Removal
1. Disconnect the battery and remove. Refer to

Chapter 414-01, Battery, Mounting and Cables

2. Remove the coolant supply tank and secure out of

the way. (RH side only) Refer to chapter 303-03

Engine Cooling.

3. Unclip the positive battery cable from the valve

Installation

cover. And secure out of the way. (RH side only)

Install in reverse order applying intake sealant to the

mating surfaces of the intake manifold. Tighten the

4. Disconnect the variable cam timing connection at

intake manifold bolts in the order illustrated below.

the front of each valve cover

5. Disconnect the ignition coils

Valve Cover LH and RH (shown)

Materials
SAE 5W-20 Premium

WSS-M2C153-H

Synthetic Blend Motor Oil

XO-5W20-QSP or

equivalent
Silicone Gasket Remover ZC-30

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303-01b-11

Engine — 5.4L (3V)

303-01b-11

IN-VEHICLE REPAIR (Continued)

6. Remove the ignition coils.

7. Disconnect the valve cover ventilation hose from

the RH valve cover. (RH side only)

8. Disconnect the PCV valve and hose. Secure out

of the way. (LH side only)

9. Remove the rear RH and front LH lifting eyes.
10. Remove the valve cover bolts.
11. Remove the valve cover.
12. Remove the valve cover gasket.

RH Valve Cover shown

Installation

Item

Description

1. Clean and inspect the sealing surfaces with

1

Bolt

silicone gasket remover and metal surface prep.

2

Valve Cover

CAUTION: Do not use metal scrapers,

3

Valve Cover Gasket

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.

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303-01b-12

Engine — 5.4L (3V)

303-01b-12

IN-VEHICLE REPAIR (Continued)

2. Apply instant adhesive completely around the

4. Position the valve cover and gasket on the

gasket groove in the valve cover. Install a new

cylinder head and install the bolts loosely. Tighten

valve cover gasket.

the bolts in the sequence shown. (RH side shown

LH side is a mirror image)

3. Apply silicone gasket and sealant in two places

where the engine front cover meets the cylinder

5. Install the rear RH and front LH lifting eyes.

head.

6. Reconnect the PCV valve and hose. (LH side

NOTE: If not secured within four minutes, the

only)

sealant must be removed and the sealing area

7. Reconnect the valve cover ventilation hose from

cleaned. To clean the sealing area, use silicone

the RH valve cover. (RH side only)

gasket remover and metal surface prep. Follow

8. Install the ignition coils.

the directions on the packaging. Failure to follow

9. Reconnect the variable cam timing connection at

this procedure can cause future oil leakage.

the front of each valve cover

10. Install the coolant supply tank (RH side only)
11. Install the battery. (RH side only)
12. Clip the positive battery cable to the valve cover.

(RH side only)

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303-01b-13

Engine — 5.4L (3V)

303-01b-13

IN-VEHICLE REPAIR (Continued)

4. Using the special tool, remove the crankshaft

Crankshaft Pulley

pulley.

Special Tool(s)

Remover, Crankshaft Vibration

Damper

303-009 (T58P-6316-D)

Installer, Crankshaft Vibration

Damper

303-102 (T74P-6316-B)

Installation
1. Apply silicone gasket or LOCKTITE 5900 or

Materials

equivalent to the Woodruff key slot on the

crankshaft pulley.

Silicone Gasket and

WSE-M4G323-A4

NOTE: The crankshaft pulley must be installed

Sealant

within four minutes after applying the silicone.

F7AZ-19554-EA or

LOCTITE 5900 or

equivalent

Removal
1. Remove the drive belt. For additional information,

refer to Section 303-05.

2. Raise and support the vehicle. For additional

information, refer to Section 100-02.

3. Remove the crankshaft pulley bolt.

2. Using the special tool, install the crankshaft

pulley.

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