2006–2008 Ford Fusion Service & Repair Manual FSM

• Covers 2006 Ford Fusion and Mercury Milan models equipped with the 2.3L dual-overhead-cam, four-valve-per-cylinder engine, including PZEV-related secondary-air details and early- and late-build accessory-drive differences.
• Supplied as a 487-page, seven-PDF set: Engine 413 pages; Electronic Engine Controls 23; Accessory Drive 19; Fuel Charging & Controls 10; Engine Ignition 9; Engine Emission Control 9; Intake Air Distribution & Filtering 4.
• Documents engine removal and installation for automatic- and manual-transaxle vehicles, full engine disassembly and assembly, cylinder-head service, timing-chain and VCT work, valve-train repair, crankshaft seals, lubrication components, and engine mounts.
• Details PCM and engine-sensor service, including CKP/CMP timing inputs, MAF/MAP load sensing, CHT, knock, HO2S/CMS feedback, and VCT control, together with coil-on-plug ignition, electronic throttle, fuel injection, EGR, PCV, and secondary-air components.
• Provides accessory-drive diagnosis and repair for belt noise, flutter, tracking, contamination, pulley alignment and runout, tensioner mechanical and dynamic checks, plus belt, tensioner, and idler-pulley removal and installation.
• Includes component-specific torque tables, torque-plus-angle tightening sequences, wear and clearance specifications, fluid and material standards, special-tool identification, exploded views, component-location drawings, and assembly-sequence illustrations.

Engine Management, Fuel, and Emissions

These PDFs reproduce Mitchell Repair service information for the 2006 2.3L Fusion and Milan, with component illustrations credited to Ford Motor Co. The electronic-engine-control chapter explains how the PCM uses CHT, CMP, CKP, MAF, MAP, heated-oxygen, catalyst-monitor, and knock-sensor inputs to control fuel delivery, ignition timing, and variable camshaft timing. Component procedures cover sensor removal and installation, the VCT oil-control solenoid, PCM replacement, and the configuration requirements associated with PCM service. The PCM article points to separate Programmable Module Installation and PATS Parameter Reset procedures; those referenced chapters are not reproduced here.

Fuel-system coverage includes sequential multi-port injection, the electronically controlled throttle body, fuel-rail and injector service, injector O-ring requirements, and the fuel-pressure-relief cross-reference used before opening the rail. Intake-air coverage identifies the air cleaner, MAF sensor, outlet pipe, resonator, and PZEV secondary-air hose arrangement. The emissions chapter covers the EGR valve, PCV valve and crankcase oil separator, plus secondary-air pump and valve service. PZEV-specific catalyst-monitor and secondary-air details are marked in the component views.

Internal Engine and Major Repair Work

The 413-page engine chapter is the core of the set. It covers in-vehicle repair of the intake manifold, valve cover, crankshaft pulley, front and rear crankshaft seals, engine front cover, timing-drive components, VCT system oil filter, camshafts, camshaft phaser and sprocket, valve springs, valve seals, tappets, cylinder head, oil pan, oil pump, pickup tube, and engine mount. Separate procedures address engine/transaxle removal and installation for automatic and manual configurations, followed by engine disassembly, cylinder-head disassembly and reassembly, and complete engine assembly.

Useful drawings include the Front End Accessory Drive exploded view, timing-chain guide and tensioner views, camshaft-phaser alignment illustrations, valve-train and cylinder-head exploded views, engine-lubrication component views, and fuel-rail/injector and HO2S/CMS layouts. Tightening-sequence diagrams are provided for the cylinder head, camshaft bearing caps, front cover, oil pan, flywheel or flexplate, and rear main-seal retainer.

Specifications, Tools, and Scope

Specification tables cover the cylinder block, pistons and pins, cylinder head, valves and springs, crankshaft, connecting rods, rings, tappets, and camshafts, including inspection limits, clearances, end play, fluid capacity, and approved materials. The material data retains Ford specifications such as WSS-M2C930-A engine oil and WSS-M97B51-A1 coolant. Listed service tools include Camshaft Alignment Plate 303-465, Crankshaft Timing Peg 303-507, Valve Spring Compressors 303-300/303-350/303-472, Valve Stem Seal Remover and Installer 303-468/303-470, Oxygen Sensor Socket 303-476, and 3-Bar Engine Support Kit 303-F072.

Two repair details are especially important. Tool 303-465 is an alignment fixture, not a counterhold; using it to resist engine rotation can damage the engine. CKP sensor removal calls for a new sensor and the alignment tool supplied with that sensor, which the chapter states is not available separately. The accessory-drive chapter also separates early- and late-build tensioner designs without giving a VIN breakpoint, so the installed layout must be identified before parts are selected.

The engine-performance diagnosis sections largely cross-reference the separate Introduction - Gasoline article rather than providing full DTC pinpoint tests or wiring schematics. Fuel-system work requires pressure relief and ignition-source control, while engine removal involves vehicle lifting, refrigerant recovery, and rated powertrain support; follow the referenced service safety procedures before beginning repair work.