Ford Fusion, Mercury Milan Repair Manual 2006-2010

This part of chapter 2 is devoted to repair procedures possible while the engine is still installed in the vehicle.

Since these procedures are based on the assumption that the engine is installed in the vehicle, if the engine has been removed from the vehicle and mounted on a stand, some of the preliminary dismantling steps outlined will not apply.

Information concerning engine/transaxles removal and replacement and engine overhaul can be found in Part C of this Chapter.

These engines are sixteen-valve, double overhead camshaft (DOHC), four-cylinder, inline type, mounted transversely at the front of the vehicle, with the transmission on the left-handed end. They incorporate an aluminum cylinder head and an aluminum cylinder block.

The two camshafts are driven by a timing chain, each operating eight valves via conventional lifters. Each camshaft rotates in five bearings that are line-bored directly in the cylinder head and the (bolted-on) bearing caps.

This means that the bearing caps are not available separately from the cylinder head, and must not be interchanged with caps from another engine.

These engines incorporate an aluminum timing chain cover and oil pan, and the crankshaft main caps are part of a one-piece lower block support.

When working on these engines, note the Torx-type (both male and female heads) and hexagon socket (Allen head) fasteners are widely used.

A good selection of sockets, with necessary adapters, will be required, so that these can be unscrewed without damage and, on reassembly, tightened to the torque wrench settings specified.

The oil pump is driven via a chain from the front of the crankshaft, using the same sprocket that drives the timing chain.

The pump forces oil through an externally mounted full-flow cartridge-type filter. From the filter, the oil is pumped into a main gallery in the cylinder block/crankcase, from where it is distributed to the crankshaft (main bearings) and cylinder head.

Note: The number and location of stud-bolts and standard bolts used to secure the valve covers may vary, depending on the year and build date of this vehicle. Keep track of the stud locations for reassembly.

1. Remove the engine access cover, if equipped.
   
   Front Valve cover | Refer to illustrations 4.2, 4.7a, 4.7b, 4.9, 4.10a, 4.10b, 4.14a, 4.14b and 4.14c
   
   
2. Disconnect the crankcase ventilation tube (see illustration).
   
   
3. Remove the ignition coils (see chapter 5). Remove the air cleaner housing (see chapter 4).
   
   
4. Disconnect the wiring harness from the valve cover and position it off to the side.
   
   
5. On 3.5L engines, remove the engine oil dip-stick and tube.
   
   
6. Disconnect the VCT electrical connector and oxygen sensor connector.
   
   
7. Loosen the valve cover bolts/nuts gradually and evenly until all are loose. Follow reverse of tightening sequence (see illustration 4.14a, 4.14b, or 4.14c). Remove the valve cover fasteners and lift the valve cover off the engine.
   
   
8. Remove and discard the valve cover gaskets and spark plug tube seals (see illustrations). Install new gaskets and seals during reassembly. Note: The spark plug tube seals can be re-used if they are in good condition and were not leaking.

• Tune-up and routine maintenance
• Four-cylinder engines - Duratec 23 (2.3L), Duratec 25 (2.5L)
• V6 engines - Duratec 30 (3.0L), Duratec 35 (3.5L) (2010 option)
• General engine overhaul procedures
• Cooling heating and air conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions and engine control systems
• 5- or 6-speed manual transaxle
• 6-speed automatic transaxle
• Clutch and driveaxles
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams