2006-2008 Ford Fusion Service & Repair Manual FSM
Ford Models Covered & Key Technical Specifications
Models: Ford Fusion, Mercury Milan
Sub-models / Variants: 2.3L Duratec 4-cylinder, PZEV variants, Automatic Transaxle, Manual Transaxle
Model Years: 2006–2008
Technical Data:
- Engine: 2.3L Duratec, 4-cylinder, 4 valve-per-cylinder, DOHC
- Firing Order: 1-3-4-2
- Oil Pressure (Hot @ 2,000 RPM): 29-39 psi (200-268 kPa)
- Oil Capacity: 4.1 qts + 0.4 qt with filter
- Crankshaft Pulley Bolt Torque: 100 Nm (Stage 1) plus 90-degree turn (Stage 2)
- Throttle Body Bolt Torque: 10 Nm (89 lb-in)
- Fuel Rail Bolt Torque: 23 Nm (17 lb-ft)
- Valve Clearance (Intake): 0.22-0.28 mm
- Valve Clearance (Exhaust): 0.27-0.33 mm
Ford Manual Features & Content Preview
- Covers 2006–2008 Ford Fusion and Mercury Milan equipped with the 2.3L Duratec 4-cylinder engine
- Official Ford Motor Co. engine performance and accessory drive documentation
- Contains 31 exploded-view component diagrams and 12 torque specification tables
- Features factory-authorized diagnostic and assembly data for engine, emission control, and accessory drive systems
Engine Management and Accessory Drive
This service manual documents internal engine specifications, electronic control system parameters, and accessory drive maintenance. It provides an in-depth breakdown of the 2.3L 4-cylinder configuration. Technicians will find comprehensive details on the variable camshaft timing (VCT) system, intake air distribution, and exhaust gas recirculation (EGR) components. The documentation covers exact service sequences for the powertrain control module (PCM), crankshaft and camshaft position sensors, and fuel injection systems. Exploded-view diagrams map out the accessory drive belt, tensioner, and idle pulley configurations. This ensures accurate identification of all mounting hardware before you even pick up a wrench.
Engine Assembly and Specification Data
Technical specifications detail critical wear limits, torque values, and fluid capacities for the 2.3L platform. If you require precise engine rebuild data, the manual provides cylinder head clearance, valve train specs, and crankshaft end play measurements. Cylinder head bolt torque values are mapped out in a strict multi-stage sequence that includes final-stage angles. It also lists exact fluid requirements, such as WSS-M2C930-A motor oil and WSS-M97B51-A1 engine coolant, for routine maintenance. Factory workshop documentation simplifies complex assemblies through clear material specifications and schematics. Always adhere strictly to OEM safety protocols and verify all specifications prior to beginning any diagnostic or mechanical procedures, as improper handling of powertrain systems carries inherent physical risks.
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