Ford Fusion, Mercury Milan Repair Manual 2006-2014

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Ford Fusion, Mercury Milan Haynes Repair Manual 2006-2014
Ford Fusion, Mercury Milan Haynes Repair Manual 2006-2014
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Item Description

The Ford Fusion, Mercury Milan repair manual by Haynes covers vehicles made between 2006 and 2014. The manual provides repair, service and maintenance information for all 4-cylinder and V6 engine Ford Fusion and Mercury Milan models. The Haynes manual is a favorite for DIY mechanics and those that are less familiar with Ford and Mercury vehicles as it provides easy-to-follow step-by-step instructions to perform a variety of tasks. The manual features a simple layout that begins with easy topics and progresses into harder tasks.

Some topics covered by this Mercury Milan and Ford Fusion repair manual include tune-ups, engine overhauls, fuel systems, clutches and driveaxles, brakes and more. There's even a chapter on the chassis electrical system that includes helpful wiring diagrams. Like other Haynes manuals, instructions are supplemented with photos, illustrations, exploded views and more to assist novice mechanics with component locations and removal.

Note: This manual DOES NOT cover hybrid models.

Book Excerpt: 2006-2014 Ford Fusion, Mercury Milan Repair Manual



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.

The Haynes 36045 - Ford Fusion / Mercury Milan Service Manual, like all Haynes manuals, is based on a complete teardown and rebuild. Haynes photographers, writers and technicians work together to capture DIY procedures that are simple to follow and full of details. Less straight forward DIY repair instructions include exploded views and diagrams to enhance the DIY mechanic's understanding - to ensure your success!

Pick up this Haynes 36045 manual today so you can save tomorrrow.

Subject: 2006, 2007, 2008, 2009, 2010, 2011, 2012, 2013, 2014 Ford Fusion, Mercury Milan service, maintenance, and repair instructions. ISBN-10: 1620921219 | ISBN-13: 9781620921210 | Haynes 36045

  • Publisher: Haynes Manuals
  • Pages: 320 - Hundreds of b&w photos and illustrations
  • Binding: Paperback - 8.5 x 11 inches
  • ISBN: 978-1-62092-121-0
  • Years: 2006 - 2014
Table of Contents
TABLE of CONTENTS: About this manual | Vehicle identification numbers | Buying parts | Maintenance techniques, tools and working facilities | Jacking and towing | Booster battery (jump) starting | Automotive chemicals and lubricants | Conversion factors | Fraction/decimal/millimeter equivalents | Safety first! | Troubleshooting
  • 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
Questions & Answers about Ford Fusion, Mercury Milan Haynes Repair Manual 2006-2014

Questions & Answers about Ford Fusion, Mercury Milan Haynes Repair Manual 2006-2014

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Customer Reviews


Jon Williams verified customerMay 26, 2016
Okay, but needs more of the 2.3 4 cylinder SEL Model with manual trans
No diagram of the Serpentine belt for the 2.3 4 cylinder engine
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Wade verified customerNovember 23, 2015
Quick shipping!
Books were available and shipped quickly. My order arrived in a few days.
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Larry verified customerMay 2, 2014
Glad to have this manual many things are similar to my Lincoln.
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