-Ford-Fusion 2007- En Motor d7c72a1084

2007 Ford Fusion SE
2007 ENGINE Engine - 2.3L - Fusion, Milan & MKZ
2007 ENGINE
Engine - 2.3L - Fusion, Milan & MKZ
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Specification
Displacement 2.3L
No. of cylinders 4
Bore/stroke 87.5/94.0
Firing order 1-3-4-2
29-39 psi
Oil pressure (hot @ 2,000 rpm)
200-268 kPa
Oil capacity 4.1 qts. + 0.4 qt with filter
Cylinder Block
87.5-87.53 mm
Cylinder bore diameter
(3.444-3.445 in)
0.008 mm
Cylinder bore maximum out-of-round
(0.0003 in)
57.020-57.038 mm
Main bearing bore diameter
(2.244-2.245 in)
0.1 mm/general
0.05 mm/200 x 200
Head gasket surface flatness
(0.004 in/general)
(0.0019 in/7.87 x 7.87)
Piston
87.5-87.51 mm
Diameter (1)
(3.444-3.445 in)
87.51-87.52 mm
Diameter (2)
(3.4452-3.4456 in)
87.52-87.53 mm
Diameter (3)
(3.444-3.446 in)
0.025-0.045 mm
Piston-to-bore clearance
(0.0009-0.0017 in)
1.203-1.205 mm
Ring groove width - top
(0.0473-0.0474 in)
1.17-1.19 mm
Ring groove width - 2nd
(0.0460-0.0468 in)
2.501-2.503 mm
Ring groove width - oil
(0.0984-0.0985 in)
Piston skirt coating thickness 0.008-0.020 mm
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08:59:48 p. m. Page 1 © 2011 Mitchell Repair Information Company, LLC.
2007 Ford Fusion SE
(0.0003-0.0007 in)
Piston Pin
20.995-21.0 mm
Diameter
(0.8266-0.8268 in)
59.6-60.4 mm
Length
(2.346-2.377 in)
0.008-0.016 mm
Piston-to-pin clearance
(0.0003-0.0006 in)
Pin-to-rod clearance Press fit
Cylinder Head
Valve lift @ zero lash (exhaust) 7.4 mm (0.29 in)
Valve lift @ zero lash (intake) 7.9 mm (0.31 in)
5.509-5.539 mm
Valve guide inner diameter
(0.216-0.218 in)
0.99-1.84 mm
Valve seat width - intake/exhaust
(0.038-0.072 in)
Valve seat angle 45 degrees
Valve seat runout 0.075 mm (0.0029 in)
31.00-31.03 mm
Valve lash adjuster bore diameter
(1.220-1.221 in)
25.015-25.040 mm
Cam bore diameter
(0.984-0.985 in)
Valve
34.85-35.15 mm
Valve head diameter - intake
(1.372-1.383 in)
29.85-30.15 mm
Valve head diameter - exhaust
(1.175-1.187 in)
5.470-5.485 mm
Valve stem diameter - intake
(0.2153-0.2159 in)
5.465-5.480 mm
Valve stem diameter - exhaust
(0.2151-0.2157 in)
Valve stem-to-guide clearance - intake 0.0027 mm (0.0009 in)
Valve stem-to-guide clearance - exhaust 0.0029 mm (0.0011 in)
Valve face runout 0.05 mm (0.001 in)
Valve face angle 45 degrees
Valve Spring - Compression Pressure
Intake and exhaust (installed) 38.667 lb
Intake (valve open) 8.9 mm (0.35 in.) of lift 97.032 lb
Exhaust (valve open) 7.4 mm of lift 93.338 lb
Free length 44.92 mm (1.768 in)
Assembled height 37.9 mm (1.492 in)
Crankshaft
51.980-52.000 mm
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2007 Ford Fusion SE
Main bearing journal diameter (2.046-2.047 in)

51.730-51.750 mm
Production repair
(2.036-2.037 in)
0.019-0.035 mm
Main bearing clearance
(0.0007-0.0013 in)
49.980-50.000 mm
Connecting rod journal diameter
(1.967-1.968 in)
49.730-49.750 mm
Production repair
(1.957-1.958 in)
0.22-0.43 mm
End play
(0.008-0.016 in)
Rings
1.17-1.185 mm
Width - top
(0.0460-0.0466 in)
1.197-1.199 mm
Width - 2nd
(0.0471-0.0472 in)
2.38-2.45 mm
Width - oil
(0.093-0.096 in)
0.16-0.31 mm
Ring gap (in bore) - top
(0.006-0.012 in)
0.33-0.48 mm
Ring gap (in bore) - 2nd
(0.012-0.018 in)
0.2-0.7 mm
Ring gap (in bore) - oil
(0.007-0.027 in)
Valve Tappet
30.97-30.98 mm
Diameter
(1.2192-1.2196 in)
Tappet-to-valve clearance - intake 0.22-0.28 mm (0.008-0.011 in)
Tappet-to-valve clearance - exhaust 0.27-0.33 mm (0.010-0.013 in)
0.02-0.06 mm
Tappet-to-bore clearance
(0.0007-0.0023 in)
Camshaft
Lobe lift - intake 8.24999 mm (0.324 in)
Lobe lift - exhaust 7.80007 mm (0.307 in)
Runout (1)a 0.03 mm (0.001 in)
0.09-0.24 mm
End play
(0.003-0.009 in)
24.96-24.98 mm
Journal diameter
(0.982-0.983 in)
0.035-0.080 mm
Journal-to-bore clearance
(0.001-0.003 in)
Connecting Rod
Bearing clearance 0.027-0.052
2007 Ford Fusion SE
(0.001-0.002 in)
1.496-1.520 mm
Bearing thickness
(0.058-0.059 in)
53.025-53.045 mm
Crank bore diameter
(2.087-2.088 in)
20.965-20.985 mm
Pin bore diameter
(0.825-0.826 in)
Length (center-to-center) 154.8 mm (6.094 in)
1.95-3.05 mm
Side clearance
(0.076-0.120 in)
0.14-0.36 mm
Axial clearance
(0.005-0.014 in)
a No. 3 Journal - Supported by No. 1 and No. 5 journals.
Item Specification
Motorcraft Metal Surface Cleaner ZC-21 WSE-M5B392-A
Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
Silicone Gasket and Sealant TA-30 WSE-M4G323-A4
High Temperature 4x4 Front Axle and Wheel
ESA-M1C198-A
Bearing Grease E8TZ-19590-A
Silicone Brake Caliper Grease and Dielectric
ESE-M1C171-A
Compound XG-3-A
Motorcraft SAE 5W-20 Premium Synthetic Blend
Motor Oil XO-5W20-QSP (US); Motorcraft SAE
WSS-M2C930-A
5W-20 Super Premium Motor Oil CXO-5W20-
LSP12 (Canada); or equivalent
Motorcraft Premium Gold Engine Coolant with
Bittering Agent (US only) VC-7-B (US); CVC-7-A WSS-M97B51-A1
(Canada) or equivalent (yellow color)
Multi-Purpose Grease XG-4 and/or XL-5 ESB-M1C93-B
Thread Sealant with PTFE TA-24 WSK-M2G350-A2
TORQUE SPECIFICATIONS
TORQUE SPECIFICATIONS
Description Nm lb-ft lb-in
A/C compressor mounting bolts 25 18 -
A/C manifold tube bolt 25 18 -
A/C tube bracket bolts 10 - 89
2007 Ford Fusion SE
A/C tube connection nut 8 - 71

A/C tube-to-condenser nut 8 - 71
Accessory drive belt tensioner bolts 25 18 -
Accessory drive belt idler pulley bolt 25 18 -
Bellhousing-to-engine bolts 48 35 -
Bellhousing-to-engine stud bolt 48 35 -
Bellhousing-to-oil pan bolta - - -
Block heater 21 15 -
Camshaft bearing cap boltsa - - -
Camshaft sprocket bolt 72 53 -
Catalytic converter boltsa - - -
Catalytic converter bracket boltsa - - -
Catalytic converter heat shield screws 10 - 89
Catalytic converter-to-cylinder head studs 17 13 -
Clutch pressure plate 29 21 -
Clutch slave cylinder bolts 22 16 -
Clutch tube bracket bolts 22 16 -
Coil-on-plug bolts 8 - 71
Coolant outlet bolts 10 - 89
Coolant pump bolts 10 - 89
Coolant pump pulley bolts 20 15 -
Coolant vent tube nuts 25 18 -
Crankshaft position (CKP) sensor boltsa - - -
Crankshaft pulley bolta - - -
Crankcase rear seal retainer plate boltsa - - -
Crankcase vent oil separator bolts 10 - 89
Cylinder head boltsa - - -
Cylinder head temperature (CHT) sensor 12 9 -
Engine front cover boltsa - - -
Engine front cover timing hole plug (lower) 12 9 -
Engine front cover timing hole plug (upper) 10 - 89
Engine front cover-to-oil pan boltsa - - -
Engine mount bolts 55 41 -
Engine mount nut 55 41 -
Engine mount bracket nuts 103 76 -
Engine mount bracket bolt 115 85 -
Engine roll-restrictor bolts 90 66 -
Engine timing plug bolt 20 15 -
Engine-to-bellhousing bolts 48 35 -
2007 Ford Fusion SE
Engine-to-bellhousing stud bolt 48 35 -

Engine wiring harness bracket nut 20 15 -
Exhaust gas recirculation (EGR) valve assembly bolts 20 15 -
EGR tube 55 41 -
Flexplate boltsa - - -
Flywheel boltsa - - -
Fuel rail bolts 23 17 -
Generator air inlet duct nuts 6 - 53
Generator B+ wire nut 6 - 53
Generator mounting bolt 47 35 -
Generator mounting stud bolts 47 35 -
Generator splash shield nuts 25 18 -
Ground wire-to-battery cable nut 10 - 89
Ground wire-to-body bolt 10 - 89
Intake manifold bolts 18 13 -
Intermediate steering shaft bolt 23 17 -
Knock sensor (KS) 20 15 -
Lower ball joint nuts 200 148 -
Lower control arm-to-strut through bolt 103 76 -
Oil filter adapter bolts 25 18 -
Oil filter cover 33 24 -
Oil filter drain plug 10 - 89
Oil pan boltsa - - -
Oil pan-to-bellhousing bolts 48 35 -
Oil pressure sender 15 11 -
Oil pan drain plug 36 27 -
Oil pump drive chain guide shoulder bolts (early build) 10 - 89
Oil pump drive chain tensioner shoulder bolt 10 - 89
Oil pump drive chain tensioner spring shoulder bolt 10 - 89
Oil pump screen and pickup tube assembly bolts 10 - 89
Oil pump sprocket bolt 25 18 -
Oil pump-to-engine block boltsa - - -
Power steering pump bolts 25 18 -
Power steering pressure (PSP) tube bolt 35 26 -
Radio frequency interference capacitor bolt 10 - 89
Rear crankshaft seal retainer boltsa - - -
RH halfshaft carrier bearing bracket bolt. 40 30 -
Secondary air injection (AIR) pump bolts 30 22 -
Secondary AIR valve bracket bolts 10 - 89
Spark plug 12 9 -
2007 Ford Fusion SE
Starter motor solenoid nut 5 - 44

Starter motor B+ wire nut 12 9 -
Starter motor mounting bolts 25 18 -
Subframe nuts 150 111 -
Subframe bracket bolts 103 76 -
Sway bar link nuts 40 30 -
Thermostat housing bolts 10 - 89
Throttle body bolts 10 - 89
Tie-rod end nuts 48 35 -
Timing chain guide bolts 10 - 89
Timing chain tensioner bolts 10 - 89
Torque converter-to-flywheel nuts 35 26 -
Transaxle ground wire bolt 10 - 89
Transaxle mount bolt 90 66 -
Valve cover boltsa - - -
Variable camshaft timing (VCT) solenoid bolta 10 - 89
VCT system oil filter plug 17 13 -
a Refer to procedure for specification.
DESCRIPTION AND OPERATION

ENGINE
The 2.3L engine is a 4 valve-per-cylinder, dual overhead camshaft engine. The engine uses a coil-on-plug
ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the ladder
assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block and to the transmission to
provide greater strength. The engine is equipped with variable camshaft timing (VCT). The VCT system
includes an oil pressure solenoid and intake camshaft actuator/sprocket assembly to control the intake valve
timing. The camshafts are mounted in the cylinder head and act against valve tappets to open and close the
valves. The camshafts are driven off the front of the cylinder head by one timing chain. The chain is driven by a
sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a powdered metal
connecting rod. The oil pump is driven by the crankshaft via a dedicated chain that is driven by the same
sprocket that drives the timing chain.
DIAGNOSTIC TESTS
ENGINE
For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION . For
driveability concerns, refer to the Introduction - Gasoline Engines .
GENERAL PROCEDURES
2007 Ford Fusion SE
VALVE CLEARANCE CHECK
1. Remove the valve cover. For additional information, refer to Valve Cover.
CAUTION: Turn the engine clockwise only, and only use the crankshaft bolt.
NOTE: Before removing the camshafts, measure the clearance of each valve at
base circle, with the lobe pointed away from the tappet. Failure to measure
all clearances prior to removing the camshafts will necessitate repeated
removal and installation and wasted labor time.
2. Use a feeler gauge to measure the clearance of each valve and record its location.
Fig. 1: Measuring Each Valve's Clearance Using A Feeler Gauge

Courtesy of FORD MOTOR CO.
NOTE: The number on the valve tappet only reflects the digits that follow the
decimal. For example, a tappet with the number 0.650 has the thickness of
3.650 mm.
NOTE: A midrange clearance is the most desirable:
l Intake: 0.22-0.28 mm (0.008-0.011 in)

l Exhaust: 0.27-0.33 mm (0.010-0.013 in)
3. Select tappets using this formula: tappet thickness = measured clearance + the base tappet thickness -
most desirable thickness.
Select the tappets and mark the installation location.
4. If any tappets do not measure within specifications, install new tappets in these locations. For additional
information, refer to Valve Train Components - Exploded View and Valve Tappets.
BALANCE SHAFT BACKLASH
2007 Ford Fusion SE
Special Tool(s)
SPECIAL TOOLS
Dial Indicator Gauge with Holding Fixture
100-002 (TOOL-4201-C)
Timing Peg, Crankshaft TDC

303-507
1. Install the Crankshaft TDC Timing Peg and rotate the crankshaft slowly clockwise until the crankshaft
balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center
(TDC).
2007 Ford Fusion SE
Fig. 2: Installing Crankshaft TDC Timing Peg
2. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .
Fig. 3: Locating Balancer Unit And Shafts Mark
NOTE: Due to the precision interior construction of the balancer unit, it should
3. not be disassembled.
Remove the 4 bolts and the balancer unit.
2007 Ford Fusion SE
Fig. 4: Locating Balancer Unit Bolts
4. Remove the adjustment shims from the seat faces of the balancer unit.
NOTE: Visually inspect the balancer unit gear for damage and verify that the shaft
turns smoothly. If there is any damage or malfunction, replace the
5. balancer unit.
Install the master adjustment shims (No. 50) on the seat faces of the balancer unit.
6. With the balancer unit shaft marks at the TDC position, slowly install the balancer unit to the cylinder
block to avoid interference between the crankshaft drive gear and the balancer unit driven gear.
Fig. 5: Locating Balancer Unit And Shafts Reference Mark
7. Install the balancer unit bolts.

l Tighten in the sequence shown in 2 stages.
l Stage 1: Tighten to 25 Nm (18 lb-ft).
2007 Ford Fusion SE
Fig. 6: Identifying Balancer Unit Bolts Tightening Sequence
8. Remove the Crankshaft TDC Timing Peg.

l Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear
and the crankshaft gear.
balance weight is up against the Crankshaft TDC Timing Peg.
l Remove the Crankshaft TDC Timing Peg.
2007 Ford Fusion SE
NOTE: Measure the backlash and verify that it is within specified range at all of
the following 6 positions: 10 degrees, 30 degrees, 100 degrees, 190
degrees, 210 degrees and 280 degrees. It will be necessary to reset the
10. measuring equipment between measurements.
NOTE: The measurement must be taken with the Dial Indicator Gauge with
Holding Fixture, a 5-mm Allen wrench and worm clamp set up as shown.
Mark the Allen wrench with a file 80 mm (3.149 in) above the driven gear
shaft center. Make sure the worm clamp and Allen wrench are not
touching the balance shaft housing.
NOTE: For an accurate measurement while measuring the gear backlash, insert a
screwdriver as shown into the crankshaft No. 1 crankweight area and set
both the rotation and the thrust direction with the screwdriver, using a
prying action as shown.
Position the Dial Indicator Gauge with Holding Fixture as shown. Measure the gear backlash.
l Position the Dial Indicator Gauge with Holding Fixture (1) on the Allen wrench 80 mm (3.149 in)
above the driven gear shaft center (2) on the balancer unit.
l Rotate the crankshaft clockwise and measure the backlash at all of the following 6 positions: 10
degrees, 30 degrees, 100 degrees, 190 degrees, 210 degrees and 280 degrees.
2007 Ford Fusion SE
Fig. 9: Measuring Gear Backlash
NOTE: If maximum backlash exceeds 0.101 mm (0.003 in), install a new balancer
11. unit.
Using the backlash measurement, select the proper shims from the Adjustment Shim Selection Table.
l Remove the balancer unit from the cylinder block.

l Install the selected adjustment shims on the seat faces of the balancer unit.
2007 Ford Fusion SE
Fig. 10: Adjustment Shim Selection Chart
balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at TDC .
2007 Ford Fusion SE
13. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder

2007 Ford Fusion SE
NOTE: Remeasure the backlash and verify that it is within specified range at all of
l If the backlash exceeds the specified range of 0.005 to 0.101 mm (0.00019 to 0.0039 in), install a
new balancer unit and repeat the procedure.
2007 Ford Fusion SE
IN-VEHICLE SERVICING
INTAKE MANIFOLD
2007 Ford Fusion SE
Fig. 15: Exploded View Of Intake Manifold With Torque Specifications (1 Of 4)

Item Part Number Description

1 7A508 Clutch slave cylinder bolt (2 required)
2 W706360 Clutch slave cylinder
Oil pressure sender electrical connector
3 14A464
(part of 12B637)
4 14A169 Wiring harness retainer (part of 12B637)
Intake manifold runner control (IMRC)
5 14A464
actuator electrical connector.
Manifold absolute pressure (MAP)
6 14A464 sensor electrical connector (part of
12B637)
Secondary air injection (AIR) vacuum
7 9D430
tube (part of 9G442)
8 N805320 Starter S-terminal nut
9 14463 Starter S-terminal wire
10 - Radiator hose retainer clip
Fig. 16: Exploded View Of Intake Manifold (2 Of 4)


Secondary air injection (AIR) pump
2007 Ford Fusion SE
11 14A464 electrical connector (part of 12B637)

12 9A486A AIR pump
13 W500032 AIR pump bolt (3 required)
Swirl control valve electrical connector
14 14A464
(2 required) (part of 12B637)
15 19D848 Brake booster vacuum supply tube
16 9D289 Evaporative emissions (EVAP) tube
Fig. 17: Exploded View Of Intake Manifold With Torque Specification (3 Of 4)


17 - Pin-type retainer (part of 12B637)
2007 Ford Fusion SE
19 9U550 Fuel rail insulator

Throttle body electrical connector (part
21 14A464
of 12B637)
22 W500305 Throttle body bolt (4 required)
23 9F991 Throttle body
24 - Throttle body gasket
Fig. 18: Exploded View Of Intake Manifold With Torque Specifications (4 Of 4)


26 W500311 Intake manifold bolt (6 required)
27 W500319 Intake manifold bolt (2 required)
28 9424 Intake manifold
29 9461 Intake manifold gasket
30 9E470 Exhaust gas recirculation (EGR) tube
31 6758 Crankcase vent hose
32 - Crankcase vent hose clamp (part of 6758)
REMOVAL AND INSTALLATION
All vehicles
2007 Ford Fusion SE
1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND
LIFTING .
2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING
AND CABLES .
3. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION
AND FILTERING - 2.3L .
4. Remove the bolt, 2 nuts and the generator air inlet duct.
l To install, tighten to 6 Nm (53 lb-in).
Fig. 19: Locating Generator Air Inlet Duct, Bolt And Nuts
5. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
Fig. 20: Locating Locking Ring And Brake Booster Vacuum Supply Tube
2007 Ford Fusion SE
6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
7. Disconnect the 2 swirl control valve electrical connectors.
8. Detach the 2 wiring harness pin-type retainers and remove the fuel rail insulator.
Fig. 21: Locating Fuel Rail Insulator Retainers

9. Detach the electrical connector pin-type retainer.
Fig. 22: Locating Electrical Connector Pin-Type Retainer

10. If equipped, remove the 7 screws and the underbody cover.
Fig. 23: Locating Underbody Cover Screws

2007 Ford Fusion SE
Vehicles equipped with manual transaxle
11. Remove the 2 bolts and position the clutch slave cylinder aside.
l To install, tighten to 22 Nm (16 lb-ft).
Vehicles with secondary air injection (AIR)
12. Disconnect the AIR pump electrical connector.

13. Remove the 3 bolts and position the AIR pump aside.
14. Disconnect the vacuum hose from the intake manifold.
All vehicles
15. Detach the radiator hose retaining clip from the intake manifold.
16. Remove the intake manifold lower bolt.
Fig. 24: Locating Intake Manifold Lower Bolt

17. Disconnect the manifold absolute pressure (MAP) sensor electrical connector.
18. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
19. Disconnect the oil pressure sender electrical connector.
l Detach the wiring harness pin-type retainer and position the wiring harness aside.
20. Remove the nut and the S-terminal wire from the starter.
21. Disconnect the throttle body electrical connector.
NOTE: Discard the throttle body gasket.
22. Remove the 4 bolts and position the throttle body aside.
2007 Ford Fusion SE
23. Detach the 2 pin-type retainers from the intake manifold.
Fig. 25: Locating Pin-Type Retainers

NOTE: There are 2 different size bolts used. Mark the location of the bolts to make
sure they are installed in their original locations.
24. Remove the 7 bolts and position the intake manifold aside to access the crankcase vent hose clamp and
the EGR tube.
25. Release the clamp and disconnect the crankcase vent hose.
26. Detach the knock sensor (KS) electrical connector pin-type retainer.
27. Remove the exhaust gas recirculation (EGR) tube.
28. Remove the intake manifold and discard the gaskets.

29. To install, reverse the removal procedure.

l Install new throttle body and intake manifold gaskets.
VALVE COVER
Material
Item Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
TA-30
2007 Ford Fusion SE
Fig. 26: Exploded View Of Valve Cover (1 Of 2)


Engine wiring harness retainers (part of
1 95318
12B637)
2 6750 Oil level indicator
3 6853 Crankcase vent hose
4 14W163 Engine wiring harness bracket
Cylinder head temperature (CHT) sensor
5 14A464
electrical connector (part of 12B637)
Variable camshaft timing (VCT) sensor
6 14A464
Camshaft position (CMP) sensor
7 14A464
2007 Ford Fusion SE
Fig. 27: Exploded View Of Valve Cover (2 Of 2)


8 6C293 Valve cover stud bolt (11 required)
9 W500215 Valve cover bolt (3 required)
10 6K271 Valve cover
11 6K260 Valve cover gasket
REMOVAL
CAUTION: During engine repair procedures, cleanliness is extremely important. Any

foreign material, including any material created while cleaning gasket
surfaces, that enters the oil passages, coolant passages or the oil pan can
cause engine failure.
1. Remove the ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
2. Remove the engine wiring harness bracket from the valve cover stud.
3. Remove the oil level indicator.
4. Disconnect the crankcase vent hose.
5. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
6. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
7. Disconnect the camshaft position (CMP) sensor electrical connector.
8. Detach all of the wiring harness retainers from the valve cover and the valve cover studs.
2007 Ford Fusion SE
9. Remove the 14 valve cover retainers and the valve cover.

l Discard the gasket.
INSTALLATION
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or
other abrasive means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths.
1. Clean and inspect the sealing surfaces.
NOTE: The valve cover must be secured within 4 minutes of silicone gasket
application. If the valve cover is not secured within 4 minutes, the sealant
must be removed and the sealing area cleaned with metal surface cleaner.
2. Apply silicone gasket and sealant to the locations shown.
Fig. 28: Applying Silicone Gasket And Sealant

3. Install the valve cover, new gasket and retainers.

l Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig. 29: Identifying Valve Cover Bolts Tightening Sequence

2007 Ford Fusion SE
4. Position the wiring harness and attach all of the wiring harness retainers to the valve cover and the valve
cover studs.
5. Connect the CMP sensor electrical connector.
6. Connect the CHT sensor electrical connector.
7. Connect the VCT solenoid electrical connector.
8. Connect the crankcase vent hose.
NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped
boss on the valve cover and fully engaged into the valve cover.
9. Install the oil level indicator.
Fig. 30: Locating Oil Level Indicator

10. Position the engine wiring harness bracket on the valve cover stud.
11. Install the ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT

FRONT SEAL
2007 Ford Fusion SE
Fig. 31: Exploded View Of Lower End Components - Crankshaft Pulley and Crankshaft Front Seal

1 6K340 Crankshaft pulley bolt
2 - Crankshaft pulley washer (part of 6K340)
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first
installing the special tools as instructed in this procedure. The
crankshaft pulley and the crankshaft timing sprocket are not keyed to
the crankshaft. The crankshaft, the crankshaft sprocket and the
pulley are fitted together by friction, using diamond washers between
the flange faces on each part. For that reason, the crankshaft
sprocket is also unfastened if you loosen the pulley bolt. Before any
repair requiring loosening or removal of the crankshaft pulley bolt,
the crankshaft and camshafts must be locked in place by the special
service tools, otherwise severe engine damage can occur.
1. For additional information, refer to the appropriate procedures.
CRANKSHAFT PULLEY
Special Tools
Illustration Tool Name Tool Number
Alignment Plate, Camshaft 303-465 (T94P-6256-CH)
Timing Peg, Crankshaft 303-507
Holding Fixture, Drive Pinion

205-126 (T78P-4851-A)
Flange
2007 Ford Fusion SE
Adapter for 205-126 (205-072-02)
Material
Item Specification
Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 WSS-M2C930-A
Super Premium Motor Oil CXO-5W20-LSP12
(Canada); or equivalent
REMOVAL
CAUTION: Do not loosen or remove the crankshaft pulley bolt without first installing
the special tools as instructed in this procedure. The crankshaft pulley and
the crankshaft timing sprocket are not keyed to the crankshaft. The
crankshaft, the crankshaft sprocket and the pulley are fitted together by
friction, using diamond washers between the flange faces on each part.
For that reason, the crankshaft sprocket is also unfastened if you loosen
the pulley bolt. Before any repair requiring loosening or removal of the
crankshaft pulley bolt, the crankshaft and camshafts must be locked in
place by the special service tools, otherwise severe engine damage can
occur.

All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING
AND LIFTING .
2. Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
2007 Ford Fusion SE

4. Remove the valve cover. For additional information, refer to Valve Cover.
CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can
result in damage to the engine. Turn the engine in the normal
direction of rotation only.
5. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
l The hole in the crankshaft pulley should be in the 6 o'clock position.
Fig. 33: Locating Hole On Crankshaft Pulley And Turning Crankshaft Clockwise
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this
tool to prevent engine rotation can result in engine damage.
NOTE: The camshaft timing slots are offset. If the special tool cannot be installed,
rotate the crankshaft one complete revolution clockwise to correctly
position the camshafts.
6. Install the special tool in the slots on the rear of both camshafts.
2007 Ford Fusion SE
Fig. 34: Identifying Special Camshaft Tool (303-465)

Automatic transaxle vehicles
7. Remove the 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the
transaxle.
Fig. 35: Locating Half Shaft Carrier Bracket Bolts And Sliding Rh Halfshaft Out Of Transaxle
All vehicles
8. Remove the engine plug bolt.
Fig. 36: Locating Engine Plug Bolt

2007 Ford Fusion SE
NOTE: The special tool will contact the crankshaft and prevent it from turning
past TDC. However, the crankshaft can still be rotated in the
counterclockwise direction. The crankshaft must remain at the TDC
position during the crankshaft pulley removal and installation.
9. Install the special tool.
Fig. 37: Identifying Special Tool (303-507)

10. Assemble the special tools using 4 hardened washers in the locations shown.
2007 Ford Fusion SE
Fig. 38: Assembling Special Tools (205-126 And 205-072-02)

CAUTION: The crankshaft must remain in the TDC position during removal of
the pulley bolt or damage to the engine can occur. Therefore, the
crankshaft pulley must be held in place with the special tool and the
bolt should be removed using an air impact wrench (1/2-in drive
minimum).
CAUTION: If the crankshaft sprocket diamond washer comes off with the
crankshaft pulley, it must be installed back onto the crankshaft.
11. Using the special tools and an air impact wrench, remove the crankshaft pulley.
l Remove and discard the crankshaft pulley bolt and washer.
l Remove the crankshaft pulley.
2007 Ford Fusion SE
Fig. 39: Locating Crankshaft Pulley Bolt And Special Tools (205-126, 205-072-02)
INSTALLATION
All vehicles
CAUTION: Do not install the crankshaft pulley bolt at this time.
NOTE: Apply clean engine oil on the seal area before installing.
1. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig. 40: Locating Crankshaft Pulley & Hole

CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front
cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
2. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the
front cover.
2007 Ford Fusion SE
Fig. 41: Locating Crankshaft Pulley Bolt

Fig. 42: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
CAUTION: The crankshaft must remain in the TDC position during installation of
bolt should be installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.
2007 Ford Fusion SE
4.
l Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place,
tighten the crankshaft pulley bolt in 2 stages:
l Stage 2: Tighten an additional 90 degrees (1/4 turn).
Fig. 43: Identifying Special Tools (205-126 And 205-072-02) & Crankshaft Pulley Bolt
5. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
Fig. 44: Aligning Crankshaft Pulley Bolt Holes

6. Remove the special tool.
Fig. 45: Identifying Special Tool
2007 Ford Fusion SE

NOTE: Only turn the engine in the normal direction of rotation.
8. Turn the crankshaft clockwise 1 and 3/4 turns.


10. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
2007 Ford Fusion SE

CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
11. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
l If it is not possible to install the bolt, the engine valve timing must be corrected by repeating this
procedure.
Fig. 49: Installing Bolt Through Crankshaft Pulley And Thread It Into Front Cover
12. Using the special tool, check the position of the camshafts.
l If it is not possible to install the special tool, the engine valve timing must be corrected by repeating
this procedure.
2007 Ford Fusion SE


2007 Ford Fusion SE

16. Install the engine plug bolt.


17. Install the RH halfshaft and the 2 halfshaft carrier bearing bracket bolts.
l Tighten to 40 Nm (30 lb-ft).
All vehicles
18. If equipped, install the underbody cover and the 7 screws.
2007 Ford Fusion SE

19. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
20. Install the valve cover. For additional information, refer to Valve Cover.
CRANKSHAFT FRONT SEAL
Special Tools
Remover, Oil Seal 303-409 (T92C-6700-CH)
Installer, Front Oil Seal 303-096 (T74P-6150-A)
Material
Item Specification
Motor Oil
REMOVAL
2007 Ford Fusion SE
occur.

1. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley.
CAUTION: Use care not to damage the engine front cover or the crankshaft
when removing the seal.
2. Using the special tool, remove the crankshaft front oil seal.
Fig. 56: Locating Crankshaft Front Oil Seal And Special Tool (303-409)
INSTALLATION
NOTE: Remove the through-bolt from the special tool.
NOTE: Lubricate the oil seal with clean engine oil.
1. Using the special tool, install the crankshaft front oil seal.
2007 Ford Fusion SE
Fig. 57: Installing Crankshaft Front Oil Seal Using Special Tool
2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley.
LOWER END COMPONENTS - EXPLODED VIEW, FLEXPLATE, FLYWHEEL AND

CRANKSHAFT REAR SEAL
Fig. 58: Exploded View Of Lower End Components - Flywheel & Crankshaft Rear Seal

1 6379 Flexplate or flywheel bolt (6 required)
2 6K375/6K390 Flexplate or flywheel
3 W500215 Engine front cover bolt (4 required)
4 W706284 Oil pan bolt (2 required)
2007 Ford Fusion SE

6 6675 Oil pan
Crankshaft rear oil seal with retainer
7 W500212
plate bolt (6 required)
Crankshaft rear oil seal with retainer
8 6K318
plate
FLEXPLATE
REMOVAL
AND LIFTING .
2. Remove the automatic transaxle. For additional information, refer to the appropriate AUTOMATIC
TRANSAXLE/TRANSMISSION - 6 SPEED or AUTOMATIC TRANSAXLE/TRANSMISSION -
FNR5 .
3. Remove the 6 bolts and the flexplate.
INSTALLATION
NOTE: Special bolts are used for installation. Do not use standard bolts.
1. Install the flexplate and tighten the bolts in the sequence shown in 3 stages.
Fig. 59: Identifying Flexplate Bolts Tightening Sequence

2. Install the automatic transaxle. For additional information, refer to the appropriate AUTOMATIC
TRANSAXLE/TRANSMISSION - 6 SPEED or AUTOMATIC TRANSAXLE/TRANSMISSION -
FNR5 .
2007 Ford Fusion SE
FLYWHEEL
REMOVAL
AND LIFTING .
2. Remove the clutch. For additional information, refer to CLUTCH .
3. Remove the 6 bolts and the flywheel.
INSTALLATION
NOTE: Special bolts are used for installation. Do not use standard bolts.
1. Install the flywheel and tighten the bolts in the sequence shown in 3 stages.

2. Install the clutch and manual transaxle. For additional information, refer to CLUTCH .
CRANKSHAFT REAR SEAL
Special Tools
Installer, Crankshaft Rear Main

303-328 (T88P-6701-B1)
Oil Seal
Material
Item Specification
2007 Ford Fusion SE
Motorcraft Metal Surface Cleaner

WSE-M5B392-A
ZC-21
WSE-M4G323-A4
TA-30
Motor Oil
REMOVAL
AND LIFTING .
2. Remove the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel.
CAUTION: If the oil pan is not removed, damage to the rear oil seal retainer joint
can occur.
3. Remove the 17 bolts and the oil pan.

4. Remove the 6 bolts and the crankshaft rear oil seal with retainer plate.
INSTALLATION
1. Using the special tool, position the crankshaft rear oil seal with retainer plate onto the crankshaft.
Fig. 61: Positioning Crankshaft Rear Oil Seal Using Special Tool (303-328)
2. Install the crankshaft rear oil seal with retainer plate and bolts.
l To install, tighten in the sequence shown to 10 Nm (89 lb-in).
2007 Ford Fusion SE
Fig. 62: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
cause scratches and gouges, which make leak paths. Use a plastic
scraping tool to remove traces of sealant.
3. Clean and inspect all the oil pan, engine front cover and cylinder block mating surfaces.
NOTE: If the oil pan is not secured within 4 minutes of sealant application, the
sealant must be removed and the sealing area cleaned with metal surface
cleaner. Allow to dry until there is no sign of wetness, or 4 minutes,
whichever is longer. Failure to follow this procedure can cause future oil
leakage.
NOTE: The oil pan must be installed and the bolts tightened within 4 minutes of
applying the silicone gasket and sealant.
4. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan. Install the oil pan. Install the 2
oil pan bolts finger-tight.
Fig. 63: Identifying Rear Oil Pan Bolts

5. Install the 4 bolts.
2007 Ford Fusion SE
Fig. 64: Locating Engine Front Cover-To-Oil Pan Bolts

6. Install the remaining oil pan bolts and tighten the oil pan bolts in the sequence shown to 20 Nm (15 lb-ft).
Fig. 65: Identifying Tightening Sequence Of Oil Pan Bolts

7. Install the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel.
ENGINE FRONT COVER
Special Tools
2007 Ford Fusion SE
Material
Item Specification
Motor Oil
WSE-M4G323-A4
TA-30
Fig. 66: Exploded View Of Engine Front Cover With Torque Specifications (1 Of 2)

2007 Ford Fusion SE
2 W500221 Coolant pump pulley bolt (3 required)

3 8509 Coolant pump pulley
Power steering pressure (PSP) switch
4 -
5 W500315 Power steering pump bolt (3 required)
6 3A696 Power steering pump
Fig. 67: Exploded View Of Engine Front Cover (2 Of 2)


Crankshaft position (CKP) sensor bolt (2
7 W701219-S
required)
8 6C315 CKP sensor
CKP sensor electrical connector (part of
9 14A464
12B637)
10 W500215 Engine front cover bolt (17 required)
11 W500320 Engine front cover bolt
14 6019 Engine front cover
REMOVAL
2007 Ford Fusion SE
occur.

AND LIFTING .
2. Loosen the 3 coolant pump pulley bolts.
3. Remove the accessory drive belt and idler pulley. For additional information, refer to ACCESSORY
DRIVE - 2.3L .
4. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley.

6. Remove the engine mount. For additional information, refer to Engine Mount.
7. Using the special tool, remove and discard the crankshaft front oil seal.
2007 Ford Fusion SE
Fig. 69: Locating Crankshaft Front Oil Seal And Special Tool (303-409)
8. Remove the 3 bolts and the coolant pump pulley.

9. Disconnect the power steering pressure (PSP) switch electrical connector.
NOTE: The bolt that is positioned under the power steering pressure tube fitting
will remain with the pump.
10. Remove the 3 power steering pump bolts and position the power steering pump aside.
11. Disconnect the crankshaft position (CKP) sensor electrical connector.
NOTE: Whenever the CKP sensor is removed, a new one must be installed, using
the alignment tool supplied with the new part.
12. Remove the 2 bolts and the CKP sensor.

l Discard the CKP sensor.
13. Remove the 22 bolts and the engine front cover.
2007 Ford Fusion SE
Fig. 70: Locating Engine Front Cover Bolts

INSTALLATION
other abrasive means to clean sealing surfaces. These tools cause
scratches and gouges which make leak paths.
1. Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE: The engine front cover must be installed and the bolts tightened within 4
minutes of applying the silicone gasket and sealant.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
2007 Ford Fusion SE
Fig. 71: Locating Silicone Gasket

3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
l Tighten the 8-mm bolts to 10 Nm (89 lb-in).
l Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
2007 Ford Fusion SE
Fig. 72: Identifying Engine Front Cover Bolts Tightening Sequence

4. Position the power steering pump and install the 3 bolts.
NOTE: The coolant pump pulley bolts should be tightened after the accessory
drive belt is installed.
5. Install the coolant pump pulley and bolts.

6. Using the special tool, install the crankshaft front oil seal.
2007 Ford Fusion SE
7. Install the engine mount. For additional information, refer to Engine Mount.
8. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley.
front cover.

NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one
must be installed using the alignment tool supplied with the new part.
10. Install a new CKP sensor.

l Do not tighten the bolts at this time.
2007 Ford Fusion SE
Fig. 75: Locating CKP Sensor Bolts

NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not
available separately.
11. Adjust the new CKP sensor with the alignment tool.
l Tighten the bolts to 7 Nm (62 lb-in).
Fig. 76: Locating CKP Sensor Alignment Tool And Bolts

12. Connect the CKP sensor electrical connector.


2007 Ford Fusion SE

15. Install the accessory drive belt and idler pulley. For additional information, refer to ACCESSORY
DRIVE - 2.3L .
16. Tighten the 3 coolant pump pulley bolts to 20 Nm (15 lb-ft).
TIMING DRIVE COMPONENTS
Special Tools
REMOVAL
occur.

2007 Ford Fusion SE
AND LIFTING .
2. Remove the engine front cover. For additional information, refer to Engine Front Cover.
3. Remove the timing chain tensioner.
1. Compress the timing chain tensioner and insert a paper clip into the hole to retain the tensioner.
2. Remove the 2 bolts and timing chain tensioner.
Fig. 79: Locating Timing Chain Tensioner Bolt

4. Remove the timing chain tensioner arm.
Fig. 80: Locating RH Timing Chain Guide

5. Remove the timing chain.
2007 Ford Fusion SE
Fig. 81: Locating Timing Chain

6. Remove the 2 bolts and the timing chain guide.
Fig. 82: Identifying Bolts And LH Timing Chain Guide

7. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft
sprocket.
Fig. 83: Locating Bolt And Exhaust Camshaft Sprocket

2007 Ford Fusion SE
8. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the camshaft phaser and
sprocket.
Fig. 84: Locating Intake Camshaft Phaser And Sprocket Bolt

INSTALLATION
1. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
Fig. 85: Locating Camshaft Sprockets And Bolts

2. Install the timing chain guide and the 2 bolts.

2007 Ford Fusion SE

3. Install the timing chain.

4. Install the timing chain tensioner arm.

5. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
l Tighten to 10 Nm (89 lb-in).
2007 Ford Fusion SE
Fig. 89: Locating Timing Chain Tensioner Bolts And Paper Clip
6. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
Fig. 90: Identifying Camshafts Sprocket Bolts

7. Install the engine front cover. For additional information, refer to Engine Front Cover.
VARIABLE CAMSHAFT TIMING (VCT) SYSTEM OIL FILTER
2007 Ford Fusion SE
Fig. 91: Exploded View Of Variable Camshaft Timing (VCT) System Oil Filter With Torque
Specification

1 W710451 Plug
Variable camshaft timing (VCT) system
2 6C683
oil filter
1. Remove the variable camshaft timing (VCT) solenoid. For additional information, refer to
ELECTRONIC ENGINE CONTROLS - 2.3L .
2. Remove the plug and the VCT system oil filter from the intake camshaft thrust cap.
CAMSHAFTS
Special Tools
2007 Ford Fusion SE
Material
Item Specification
WSE-M4G323-A4
TA-30
Motor Oil
REMOVAL

CAUTION: Do not rotate the camshafts or crankshaft unless instructed to do so in

this procedure. Rotating the camshafts or crankshaft with timing
components loosened or removed can cause serious damage to the
valves or pistons.
All vehicles
AND LIFTING .
2007 Ford Fusion SE

5. Check the valve clearance. For additional information, refer to Valve Clearance Check.
2007 Ford Fusion SE

transaxle.
All vehicles

2007 Ford Fusion SE
position during the camshaft removal and installation.

front cover.
2007 Ford Fusion SE

12. Remove the lower timing hole plug from the engine front cover.
Fig. 99: Locating Lower Front Cover Timing Hole Plug

13. Remove the upper timing hole plug from the engine front cover.
Fig. 100: Locating Upper Front Cover Timing Hole Plug

14. Reposition the special tool to the slot on the rear of the intake camshaft only.
Fig. 101: Identifying Special Tool (303-465) In Slots On Rear Of Camshafts

2007 Ford Fusion SE
NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows
the plunger to collapse and create slack in the timing chain. Installing the
M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will lock
the tensioner arm in a retracted position and allow enough slack in the
timing chain for removal of the exhaust camshaft gear.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing
hole.
l Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse
the timing chain tensioner plunger.
l Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner
arm in the retracted position.
Fig. 102: Using Small Pick Tool To Release Timing Chain Tensioner Ratchet Through Lower Front
Cover Timing Hole
drive gear.
2007 Ford Fusion SE
Fig. 103: Identifying Exhaust Camshaft Drive Gear Bolt


18. Remove the timing chain from the intake camshaft drive gear.
2007 Ford Fusion SE
Fig. 105: Locating Timing Chain On Intake Camshaft Drive Gear

19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
Fig. 106: Locating Camshaft Lobe

CAUTION: Failure to follow the camshaft loosening procedure can result in

damage to the camshafts.
20. Remove the camshafts from the engine.

l Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is
released from the camshaft bearing caps.
l Remove the bolts and the camshaft bearing caps.
l Remove the camshafts.
2007 Ford Fusion SE
Fig. 107: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts

21. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference
during installation.
l If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and
sprocket.
Fig. 108: Locating Marks On Camshaft Phaser

INSTALLATION
All vehicles
NOTE: If new parts are installed, transfer the reference marks made during
disassembly to the new parts.
1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and
the bolt.
l Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt
to 72 Nm (53 lb-ft).
2007 Ford Fusion SE

CAUTION: Install the camshafts with the alignment slots in the camshafts lined
up so the Camshaft Alignment Plate can be installed without rotating
the camshafts. Make sure the lobes on the No. 1 cylinder are in the
same position as noted in the removal procedure. Rotating the
camshafts when the timing chain is removed, or installing the
camshafts 180 degrees out of position can cause severe damage to
the valves and pistons.
NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
2. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3
stages:
l Stage 1: Tighten the camshaft bearing cap bolts until finger tight.
l Stage 2: Tighten to 7 Nm (62 lb-in).
Fig. 110: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts

2007 Ford Fusion SE

4. Install the timing chain on the intake camshaft drive gear.

NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft
timing sprocket and the intake camshaft drive gear in order to install the
exhaust camshaft drive gear onto the exhaust camshaft.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust
camshaft.
l Hand-tighten the bolt.
Fig. 113: Locating Exhaust Camshaft Drive Gear Bolt
2007 Ford Fusion SE
NOTE: Releasing the tensioner arm will remove the slack from the timing chain.
6. Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner
arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt
Fig. 114: Locating Camshaft Drive Gear Bolt

2007 Ford Fusion SE



11. Install the upper timing hole plug in the engine front cover.
2007 Ford Fusion SE

12. Apply silicone gasket and sealant to the threads of the lower timing hole plug.
l Install the lower timing hole plug in the engine front cover.



2007 Ford Fusion SE
All vehicles

17. Install the variable camshaft timing (VCT) solenoid. For additional information, refer to ELECTRONIC
ENGINE CONTROLS - 2.3L .
CAMSHAFT PHASER AND SPROCKET
Special Tools
Material
Item Specification
WSE-M4G323-A4
TA-30
2007 Ford Fusion SE
Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20
WSS-M2C930-A
REMOVAL

CAUTION: Do not rotate the camshafts or crankshaft unless instructed to do so in

this procedure. Rotating the camshafts or crankshaft with timing
components loosened or removed can cause serious damage to the
valves or pistons.
All vehicles
AND LIFTING .

2007 Ford Fusion SE

transaxle.
2007 Ford Fusion SE
All vehicles

position during the camshaft removal and installation.
2007 Ford Fusion SE

front cover.

12. Remove the lower timing hole plug from the engine front cover.
2007 Ford Fusion SE

13. Remove the upper timing hole plug from the engine front cover.

14. Reposition the special tool to the slot on the rear of the intake camshaft only.

NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows
the plunger to collapse and create slack in the timing chain. Installing the
M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will lock
the tensioner arm in a retracted position and allow enough slack in the
2007 Ford Fusion SE
timing chain for removal of the exhaust camshaft gear.
15. Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing
hole.
l Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse
the timing chain tensioner plunger.
l Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner
arm in the retracted position.
Fig. 132: Using Small Pick Tool To Release Timing Chain Tensioner Ratchet Through Lower Front
Cover Timing Hole
drive gear.
2007 Ford Fusion SE
Fig. 133: Identifying Exhaust Camshaft Drive Gear Bolt


18. Remove the timing chain from the intake camshaft drive gear.
2007 Ford Fusion SE



damage to the intake camshaft.
20. Remove the intake camshaft from the engine.

l Loosen the intake camshaft bearing cap bolts, in the sequence shown, one turn at a time until all
tension is released from the camshaft bearing caps.
l Remove the intake camshaft.
2007 Ford Fusion SE
Fig. 137: Identifying Loosening Sequence Of Intake Camshaft Bearing Cap Bolts
21. Mark the camshaft phaser and sprocket and the camshaft for reference during installation.

22. Place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.
INSTALLATION
All vehicles
NOTE: If new parts are installed, transfer the reference marks made during
disassembly to the new parts.
1. Position the camshaft in a soft-jawed vise. Install the camshaft phaser and sprocket and the bolt.
l Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt
2007 Ford Fusion SE

CAUTION: Install the intake camshaft with the alignment slots in the camshafts
lined up so the Camshaft Alignment Plate can be installed without
rotating the camshafts. Make sure the lobes on the No. 1 cylinder are
in the same position as noted in the removal procedure. Rotating the
NOTE: Lubricate the intake camshaft journals and bearing caps with clean engine
oil.
2. Install the intake camshafts and bearing caps. Tighten the intake camshaft bearing caps in the sequence
shown in 3 stages:
l Stage 1: Tighten the intake camshaft bearing cap bolts until finger tight.
Fig. 140: Identifying Tightening Sequence Of Intake Camshaft Bearing Caps Bolts
2007 Ford Fusion SE

4. Install the timing chain on the intake camshaft drive gear.

NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft
timing sprocket and the intake camshaft drive gear in order to install the
exhaust camshaft drive gear onto the exhaust camshaft.
5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust
camshaft.
l Hand-tighten the bolt.
Fig. 143: Locating Exhaust Camshaft Drive Gear Bolt
2007 Ford Fusion SE
NOTE: Releasing the tensioner arm will remove the slack from the timing chain.
6. Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner
arm.
7. Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt
Fig. 144: Locating Camshaft Drive Gear Bolt

2007 Ford Fusion SE



11. Install the upper timing hole plug in the engine front cover.
2007 Ford Fusion SE

12. Apply silicone gasket and sealant to the threads of the lower timing hole plug.
l Install the lower timing hole plug in the engine front cover.



2007 Ford Fusion SE
All vehicles

17. Install the variable camshaft timing (VCT) solenoid. For additional information, refer to ELECTRONIC
ENGINE CONTROLS - 2.3L .
VALVE TRAIN COMPONENTS - EXPLODED VIEW
Fig. 152: Exploded View Of Valve Train Components


1 6500 Valve tappet (16 required)
2 6518 Valve collet (16 required)
2007 Ford Fusion SE
3 6514 Valve spring retainer (16 required)

4 6513 Valve spring (16 required)
5 6517 Valve seal (16 required)
VALVE SPRINGS
Special Tools
Compressor, Valve Spring 303-350 (T89P-6565-A)
Compressor, Valve Spring 303-300 (T87C-6565-A)
Compressor, Valve Spring 303-472 (T94P-6565-AH)
Material
Item Specification
Motor Oil
Multi-Purpose Grease
ESB-M1C93-B
XG-4 and/or XL-5
REMOVAL

2007 Ford Fusion SE
AND LIFTING .
2. Remove the camshafts. For additional information, refer to Camshafts.
CAUTION: If the camshafts and valve tappets are to be reused, mark the location
of the valve tappets to make sure they are assembled in their original
positions.
NOTE: The number on the valve tappets only reflects the digits that follow the
3.650 mm.
3. Remove and inspect the valve tappets. For additional information, refer to ENGINE SYSTEM -
GENERAL INFORMATION .
4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
WARNING: Always wear protective goggles when working with compressed air.
This can prevent injury. Failure to follow these instructions can
result in personal injury.
CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect

the compressed air from the cylinder until the valve spring, valve
spring retainer and valve collet is installed.
5. Connect compressed air supply to the No. 1 cylinder.
NOTE: Place all parts in order to one side.
6. Apply compressed air to the cylinder and remove the valve spring.
l Using the special tools, compress the valve spring and remove the valve collet, using some grease
and a small screwdriver.
l Remove the valve spring retainer and the valve spring.
Fig. 153: Identifying Special Tools (303-300, 303-350, 303-472)

2007 Ford Fusion SE
INSTALLATION
NOTE: Check the seating of the valve collet.
1. Using the special tools, install the valve spring.

l Insert the valve spring and the valve spring retainer.
l Compress the valve spring and install the valve collet using some grease and a small screwdriver.

2. Disconnect the compressed air supply.

3. Repeat the appropriate removal and installation steps for all of the other cylinders.
4. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
5. Coat the valve tappets with clean engine oil and insert them.
6. Install the camshafts. For additional information, refer to Camshafts.
VALVE SEALS
Special Tools
2007 Ford Fusion SE
Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH)
Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)
Slide Hammer 307-005 (T59L-100-B)
Material
Item Specification
Motor Oil
ESB-M1C93-B
XG-4 and/or XL-5
REMOVAL

AND LIFTING .
2007 Ford Fusion SE
positions.
3.650 mm.
4. Remove the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
WARNING: Always wear protective goggles when working with compressed air.
This can prevent injury. Failure to follow these instructions can
result in personal injury.
CAUTION: Use compressed air at 7 to 10 bars (100-150 psi). Do not disconnect

the compressed air from the cylinder until the valve spring, valve
spring retainer and valve collet is installed.
5. Connect compressed air supply to the No. 1 cylinder.
NOTE: Place all parts in order to one side.
6. Apply compressed air to the cylinder and remove the valve spring.
l Using the special tools, compress the valve spring and remove the valve collet, using some grease
and a small screwdriver.
l Remove the valve spring retainer and the valve spring.

7. Using the special tools, remove and discard the valve seal.
2007 Ford Fusion SE
Fig. 156: Removing Valve Seal Using Special Tools (307-005, 303-468)
INSTALLATION
1. Install the valve stem seal installation sleeve.
Fig. 157: Identifying Valve Stem Seal Installation Sleeve

2. Using the special tool, install the valve seal.
Fig. 158: Installing Valve Seal Using Special Tool (303-470)

NOTE: Check the seating of the valve collet.
3. Using the special tools, install the valve spring.
2007 Ford Fusion SE
l Insert the valve spring and the valve spring retainer.

l Compress the valve spring and install the valve collet using some grease and a small screwdriver.

4. Disconnect the compressed air supply.

5. Repeat the appropriate removal and installation steps for all of the other cylinders.
6. Install the spark plugs. For additional information, refer to ENGINE IGNITION - 2.3L .
7. Coat the valve tappets with clean engine oil and insert them.
8. Install the camshafts. For additional information, refer to Camshafts.
VALVE TAPPETS
Material
Item Specification
Motor Oil

AND LIFTING .
2007 Ford Fusion SE
positions.
3.650 mm.
3. Remove and inspect the valve tappets. For additional information refer to ENGINE SYSTEM -
l Coat the valve tappets with clean engine oil prior to installation.
CYLINDER HEAD
Special Tools
3-Bar Engine Support Kit 303-F072
Lifting Brackets, Engine 303-050 (T70P-6000)
Material
Item Specification
Motor Oil
Silicone Gasket Remover
-
ZC-30
Motorcraft Metal Surface Prep
-
ZC-31
WSE-M4G323-A4
TA-30
2007 Ford Fusion SE
Fig. 160: Exploded View Of Cylinder Head Components With Torque Specifications (1 Of 3)

1 W711684 Engine mount bracket bolt
Radio frequency interference capacitor
2 W705936
bolt
3 19A095 Radio frequency interference capacitor
4 W520214 Engine mount bracket nut (2 required)
5 6A094 Engine mount bracket
6 6F012 Engine mount
7 W711578 Engine mount nut
8 W706496 Engine mount bolt (2 required)
9 - Secondary air injection (AIR) valve
2007 Ford Fusion SE
bracket bolt (2 required)

10 - AIR valve bracket
11 - Evaporative emissions tube bundle clip
13 9A486A AIR pump
AIR pump electrical connector (part of
14 14A464
12B637)

Variable camshaft timing (VCT) oil
1 W500211
control solenoid bolt
2 6M280 VCT oil control solenoid
3 W500301 Intake camshaft bearing cap bolt
4 6A258 Intake camshaft bearing cap
5 W703383 Camshaft bearing cap bolt (20 required)
6 6A284 Camshaft bearing cap (9 required)
7 6A272 Exhaust camshaft
8 6A267 Intake camshaft
2007 Ford Fusion SE

Exhaust gas recirculation (EGR) coolant
1 W52592
tube clamp
2 18K580 EGR coolant hose
3 - Engine coolant vent hose clamp
4 8W005 Engine coolant vent hose
5 - Heater hose clamp
6 18K580 Heater hose
7 8287 Upper radiator hose clamp
8 8260 Upper radiator hose
9 W525958 Bypass hose clamp
10 8548 Bypass hose
11 6065 Cylinder head bolt (10 required)
Engine coolant temperature (ECT) sensor
12 14A464
EGR valve electrical connector (part of
13 14A464
12B637)
14 6050 Cylinder head
15 6051 Cylinder head gasket
2007 Ford Fusion SE
REMOVAL
occur.

All vehicles
AND LIFTING .
2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL
INFORMATION .
4. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
5. Remove the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
6. Remove the generator. For additional information, refer to GENERATOR AND REGULATOR .
7. Remove the fuel supply rail. For additional information, refer to FUEL CHARGING AND
CONTROLS - 2.3L .
8. Remove the intake manifold. For additional information, refer to Intake Manifold.
9. Disconnect the secondary air injection (AIR) pump electrical connector.

All vehicles
11. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
12. Remove the engine mount bracket bolt.
13. Install the special tool and a suitable length of chain to the threaded hole in the LH side of the engine
block.
2007 Ford Fusion SE

14. Install the special.

l Using the special tool, lift the engine 25 mm (0.98 in).
Fig. 164: Lifting Engine Using Special Tool (303-050, 313-F072)

15. Remove the nut, 2 bolts and the engine mount.

16. Lower the engine 25 mm (0.98 in).
17. Remove the 2 nuts and the engine mount bracket.
18. Remove the timing drive components. For additional information, refer to Timing Drive Components.

2007 Ford Fusion SE

21. Remove the bolt and the variable camshaft timing (VCT) solenoid.



positions.
2007 Ford Fusion SE
3.650 mm.
24. Detach the retaining clip and position the evaporative emissions (EVAP) tube bundle aside.
Fig. 168: Locating Evaporative Emissions (EVAP) Tube Bundle Retaining Clip
25. Disconnect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose from the
engine coolant outlet.
26. Disconnect the engine coolant temperature sensor (ECT) electrical connector.
27. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
28. Disconnect the coolant hose from the EGR valve.
29. Remove the 2 bolts and position AIR valve bracket aside.
All vehicles
30. Remove the 10 bolts and the cylinder head.

l Discard the bolts.
INSTALLATION
All vehicles
cause scratches and gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions
contained on the packaging of the silicone gasket remover and the
2007 Ford Fusion SE
metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.
1. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
2. Clean the cylinder head bolt holes in the cylinder block. Make sure all coolant, oil or other foreign
material is removed.
3. Inspect the cylinder head for distortion. For additional information, refer to ENGINE SYSTEM -
Fig. 169: Identifying Silicone Gasket And Sealant Location

5. Install a new head gasket.
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New
cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
6. Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
2007 Ford Fusion SE
l Stage 4: Turn 90 degrees.

l Stage 5: Turn an additional 90 degrees.
Fig. 170: Identifying Tightening Sequence Of Cylinder Head Bolts

7. Position AIR valve bracket and install the 2 bolts.

All vehicles
8. Connect the coolant hose to the EGR valve.

9. Connect the EGR valve electrical connector.
10. Connect the ECT electrical connector.
11. Connect the upper radiator hose, coolant bypass hose, heater hose and coolant vent hose to the engine
coolant outlet.
12. Attach the EVAP tube bundle retaining clip retaining clip.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
2007 Ford Fusion SE
13. Install the valve tappets.
stages:
l Stages 1: Tighten the camshaft bearing cap bolts until finger tight.
l Stages 2: Tighten to 7 Nm (62 lb-in).
l Stages 3: Tighten to 16 Nm (12 lb-ft).


2007 Ford Fusion SE
16. Install the VCT solenoid and bolt.

17. Install the timing drive components. For additional information, refer to Timing Drive Components.
18. Install the engine mount bracket and the 2 nuts.
19. Using the special too, lift the engine 25 mm (0.98 in).
Fig. 174: Lifting Engine Using Special Tool (303-050, 313-F072)

20. Install the engine mount, nut and 2 bolts.

21. Lower the engine 25 mm (0.98 in).

22. Install the engine mount bracket bolt.
23. Install the radio frequency interference capacitor and bolt to the engine mount bracket.
24. Install the AIR pump and the 3 bolts.

25. Connect the AIR pump electrical connector.
All vehicles
26. Install the intake manifold. For additional information, refer to Intake Manifold.
27. Install the fuel supply rail. For additional information, refer to FUEL CHARGING AND CONTROLS -
2.3L .
28. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
29. Install the catalytic converter. For additional information, refer to EXHAUST SYSTEM .
30. Install the degas bottle. For additional information, refer to ENGINE COOLING .
31. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
2007 Ford Fusion SE
ENGINE LUBRICATION COMPONENTS - EXPLODED VIEW
Fig. 175: Exploded View Of Oil Filter Element, Oil Filter Adapter & Oil Pressure Sender With Torque
Specifications

1 6C684 Oil filter drain plug
2 W707718 Oil filter drain plug O-ring seal
3 6A832 Oil filter cover
4 6885 Oil filter cover O-ring seal
5 6744 Oil filter element
6 6884 Oil filter adapter
Secondary air injection (AIR) pump
7 14A464
2007 Ford Fusion SE
8 9A486A AIR pump

10 W500225 Oil filter adapter bolt (4 required)
11 9278 Oil pressure sender
Oil pressure sender electrical connector
12 14A464
(part of 12B637)
13 6A636 Oil filter adapter gasket
14 7A508 Clutch slave cylinder bolt (2 required)
15 W706360 Clutch slave cylinder
NOTE: Automatic transmission shown, manual transmission similar.
Fig. 176: Exploded View Of Oil Pan, Oil Pump Screen & Pickup Tube With Torque Specifications

1 W706215 Upper bellhousing-to-engine bolts
Front lower bellhousing-to-engine bolt (1
2 W500125 required for automatic transmission) (2
required for manual transmission)
2007 Ford Fusion SE
Fig. 177: Exploded View Of Engine Lubrication Components With Torque Specifications

3 W500120 Rear lower engine-to-bellhousing bolt
Rear lower engine-to-bellhousing stud
4 W500124
bolt
5 W500122 Oil pan-to-bellhousing bolt (2 required)
6 W500122 Bellhousing-to-oil pan bolt
7 6730 Oil pan drain plug
Engine front cover-to-oil pan bolt (4
8 W500215
required)
2007 Ford Fusion SE
11 6675 Oil pan

Oil pump screen and pickup tube bolt (2
12 W706282
required)
13 6622 Oil pump screen and pickup tube
14 6625 Oil pump screen and pickup tube gasket
Fig. 178: Exploded View Of Oil Pump With Torque Specifications


Oil pump chain guide shoulder bolt (2
1 W703651
required) (early build)
2 6M256 Oil pump chain guide (early build)
Oil pump drive chain tensioner shoulder
3 W703651
bolt
4 6C271 Oil pump drive chain tensioner
5 6A895 Oil pump drive chain
6 W704397 Oil pump sprocket bolt
7 6652 Oil pump sprocket
8 W703647 Oil pump bolt (4 required)
9 6600 Oil pump
2007 Ford Fusion SE
OIL FILTER ELEMENT
Material
Item Specification
Motor Oil
REMOVAL
AND LIFTING .
2. If equipped, remove the 2 screws and the oil filter access cover.
Fig. 179: Locating Oil Filter Access Cover And Screws

3. Loosen the oil filter drain plug.

4. Using a cup-style oil filter wrench, loosen the oil filter cover one turn.
5. Remove the oil filter drain plug and drain the engine oil from the oil filter and adapter.
l Remove and discard the oil filter drain plug O-ring seal.
6. Remove the oil filter cover and oil filter element.

l Discard the oil filter element.
l Remove and discard the oil filter cover O-ring seal.
INSTALLATION
1. Wipe clean the oil filter cover and mounting surface on the oil filter adapter.
NOTE: Lubricate the oil filter cover O-ring seal with clean engine oil.
2. Install a new oil filter cover O-ring seal.
2007 Ford Fusion SE
CAUTION: Do not over tighten the oil filter cover. Over tightening the oil filter
cover may damage the cover or O-ring seal and result in an oil leak.
3. Install a new oil filter element and the oil filter cover.
l Using a cup-style oil filter wrench, tighten to 33 Nm (24 lb-ft).
NOTE: Lubricate the oil filter drain plug O-ring seal with clean engine oil.
4. Install a new oil filter drain plug O-ring seal.
CAUTION: Do not over tighten the oil filter drain plug. Over tightening the oil
filter drain plug may damage the drain plug, O-ring seal or cover and
result in an oil leak.
5. Install the oil filter drain plug.

6. If equipped, install the oil filter access cover and the 2 screws.
OIL FILTER ADAPTER
All vehicles
AND LIFTING .

3. Remove the oil filter element. For additional information, refer to Oil Filter Element.
2007 Ford Fusion SE
Vehicles equipped secondary air injection (AIR)

All vehicles
NOTE: Discard the gasket.
8. Remove the 4 bolts and the oil filter adapter.

ENGINE OIL PRESSURE (EOP) SWITCH
Material
Item Specification
Thread Sealant with PTFE
WSK-M2G350-A2
TA-24
All vehicles
AND LIFTING .
2007 Ford Fusion SE
All vehicles

5. Remove the oil pressure sender.

l Apply pipe sealant with Teflon® to the oil pressure sender threads.
OIL PAN
Material
Item Specification
Motor Oil
WSE-M5B392-A
ZC-21
WSE-M4G323-A4
TA-30
REMOVAL
All vehicles
AND LIFTING .
2. Remove the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION AND
FILTERING - 2.3L .
Automatic transmission
3. Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
All vehicles
2007 Ford Fusion SE
CAUTION: To prevent damage to the transmission, do not loosen the

transmission-to-engine bolts more than 5 mm (0.19 in).
4. Loosen the 3 upper transaxle-to-engine bolts 5 mm (0.19 in).


6. Loosen the 1 (automatic transmission) or 2 (manual transmission) front lower bellhousing-to-engine bolt
(s) 5 mm (0.19 in).
7. Loosen the rear lower engine-to-bellhousing bolt and stud bolt 5 mm (0.19 in).
8. Remove the 2 oil pan-to-bellhousing bolts.
9. Remove the bellhousing-to-oil pan bolt.
10. Slide the transmission rearward 5 mm (0.19 in).
11. Drain the engine oil.
l Install the drain plug.
12. Remove the 4 engine front cover-to-oil pan bolts.

INSTALLATION
All vehicles
1. Clean and inspect all mating surfaces.
2007 Ford Fusion SE

leakage.
2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan-to-engine block and to the oil
pan-to-engine front cover mating surface.
Fig. 183: Identifying Silicone Gasket And Sealant

3. Position the oil pan onto the engine and install the oil pan bolts finger-tight.
4. Install the 4 engine front cover-to-oil pan bolts.
Fig. 184: Locating Engine Front Cover-To-Oil Pan Bolts

2007 Ford Fusion SE
5. Tighten the oil pan bolts in the sequence shown.


6. Alternate tightening the 1 front and 1 rear lower bolts to slide the transmission and engine together.
7. Tighten the remaining front lower bolt (manual transmission) and rear lower stud bolt.
8. Install the bellhousing-to-oil pan bolt.

9. Install the 2 oil pan-to-bellhousing bolts.


11. Tighten the 3 top bellhousing-to-engine bolts.

Automatic transmission
12. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
2007 Ford Fusion SE
All vehicles
13. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION
AND FILTERING - 2.3L .
14. Fill the engine with clean engine oil.
OIL PUMP SCREEN AND PICKUP TUBE
AND LIFTING .
2. Remove the oil pan. For additional information, refer to Engine Lubrication Components - Exploded
View and Oil Pan.
NOTE: Discard the gasket and clean and inspect the gasket mating surfaces.
3. Remove the 2 bolts and the oil pump screen and pickup tube.
OIL PUMP
Material
Item Specification
Motor Oil
WSE-M4G323-A4
TA-30
WSE-M5B392-A
ZC-21
REMOVAL
NOTE: Early build engines are equipped with an oil pump drive chain guide. Late build
engines do not have an oil pump drive chain guide. Also, late build engines use
an updated design for the oil pump drive chain and tensioner. Therefore, the oil
pump drive components are not interchangeable between early build and late
build engines.
All vehicles
2007 Ford Fusion SE
1. With the engine in NEUTRAL, position it on a hoist. For additional information, refer to JACKING
AND LIFTING .
2. Remove the engine front cover. For additional information, refer to Engine Front Cover.
3. Drain the engine oil, then install the drain plug.

NOTE: Discard the gasket and clean and inspect the gasket mating surfaces.
6. Remove the 2 bolts and the oil pump screen and pickup tube.
Early build vehicles
7. Remove the oil pump drive chain tensioner and guide.

1. Release the tension on the tensioner spring.
2. Remove the 2 shoulder bolts and the tensioner.
3. Remove the 2 shoulder bolts and the guide.
Fig. 187: Locating Tensioner Shoulder Bolts, Tensioner Spring And Guide
Late build vehicles
8. Remove the oil pump drive chain tensioner.

2. Remove the tensioner and the 2 shoulder bolts.
2007 Ford Fusion SE
Fig. 188: Locating Shoulder Bolts & Tensioner

All vehicles
9. Remove the chain from the oil pump sprocket.

10. Remove the bolt and oil pump sprocket.
11. Remove the 4 bolts and the oil pump.
INSTALLATION
All vehicles
NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface
cleaner.
1. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
Fig. 189: Identifying Oil Pump Bolts Tightening Sequence

2. Install the oil pump sprocket and bolt.

3. Install the chain onto the oil pump sprocket.
2007 Ford Fusion SE
Late build vehicles
4. Install the oil pump drive chain tensioner shoulder bolt.

Fig. 190: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
5. Install the oil pump drive chain guide and the shoulder bolts.
Fig. 191: Locating Oil Pump Chain Guide & Shoulder Bolts
All vehicles
6. Install the oil pump chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
2007 Ford Fusion SE
Fig. 192: Locating Oil Pump Chain Tensioner And Bolt

7. Install the oil pump screen and pickup tube and the 2 bolts.
scraping tool to remove traces to sealant.
8. Clean all mating surfaces with metal surface cleaner.
leakage.
9. Apply a 2.5 mm (0.09 in) bead of sealant gasket and sealant to the oil pan.
l Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.

10. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the
2007 Ford Fusion SE
engine block.
Fig. 194: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using
Suitable Straightedge
11. Install the remaining oil pan bolts.

l Tighten in the sequence shown to 25 Nm (18 lb-ft).


13. Install the engine front cover. For additional information, refer to Engine Front Cover.
2007 Ford Fusion SE
ENGINE MOUNT
Special Tools
3-Bar Engine Support Kit 303-F072
Fig. 196: Exploded View Of Engine Mount With Torque Specifications


1 W705936 Radio interference capacitor bolt
2 19A095 Radio frequency interference capacitor
3 W711684 Engine mount bracket bolt
4 W520214 Engine mount bracket nut (2 required)
5 6A094 Engine mount bracket
6 6F012 Engine mount
7 W711578 Engine mount nut
8 W706496 Engine mount bolt (2 required)
2007 Ford Fusion SE
AND LIFTING .
2. Remove the engine coolant degas bottle. For additional information, refer to ENGINE COOLING .
l Attach the special tool to the front and rear engine lifting eyes.
Fig. 197: Identifying Special Tool (303-F072)

4. Remove the bolt and the radio frequency interference capacitor.

5. Remove the engine mount bracket bolt.

6. Use the special tool to raise the engine 25 mm (0.98 in).
Fig. 198: Identifying Special Tool (303-F072)

7. Remove the 2 engine mount bracket nuts.

8. Remove the nut, 2 bolts and the engine mount.

NOTE: If the engine mount bracket is to be removed, the engine must be lowered
2007 Ford Fusion SE
to avoid contact between the A/C tubes and the engine mount bracket.
9. Use the special tool to lower the engine 25 mm (0.98 in).

l Remove the engine mount bracket.
REMOVAL
ENGINE - AUTOMATIC TRANSAXLE
Special Tools
Separator, Ball joint 205-592
Adapter for 204-592 204-592/1
Tie-Rod End Remover 211-105
Heavy Duty Floor Crane 014-00071 or equivalent
303-D089 (D93P-6001-A3) or
Spreader Bar
equivalent
Powertrain Lift 014-00765
2007 Ford Fusion SE
Universal Adapter Brackets 014-0001
303-D095 (D94L-6001-A) or
Lifting Bracket Set, Engine
equivalent
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when
working on or near any fuel-related components. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in personal injury.
All vehicles
AND LIFTING .
INFORMATION .
AND CABLES .
4. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL
SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS
5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
6. Remove the 2 nuts and the steering joint cover.
Fig. 199: Locating Steering Joint Cover And Nuts

CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected

from the gear or damage to the clockspring can occur. If there is
evidence that the intermediate shaft has rotated, the clockspring
must be removed and recentered. For additional information, refer to
SUPPLEMENTAL RESTRAINT SYSTEM .
2007 Ford Fusion SE
NOTE: Index the steering column shaft position to the steering gear for reference
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
Fig. 200: Locating Steering Column Shaft Index Mark And Bolt
8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump.
l Route the PSP tube out the bottom of the engine compartment.
Fig. 201: Locating Power Steering Pressure (PSP) Tube Bolt

9. Drain the cooling system. For additional information, refer to ENGINE COOLING .
2007 Ford Fusion SE

11. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
CAUTION: The steering gear-to-dash seal must be removed or it will be

damaged when lowering the subframe.
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger
compartment.
Fig. 203: Locating Steering Gear-To-Dash Seal Clips

13. Remove the engine roll restrictor bolt.
Fig. 204: Locating Engine Roll Restrictor Bolt

14. Remove the 4 screws and position the RH fender splash shield aside.
2007 Ford Fusion SE
Fig. 205: Locating RH Fender Splash Shield Screws

15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
Fig. 206: Locating Splash Shield Pin-Type Retainers

16. Remove the 4 screws and position the LH fender splash shield aside.
Fig. 207: Locating LH Fender Splash Shield Screws

17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
2007 Ford Fusion SE
Fig. 208: Locating LH Splash Shield Pin-Type Retainers

NOTE: LH shown, RH similar.
18. Remove the cotter pins and nuts from the tie-rod ends.
Fig. 209: Locating Tie-Rod Ends Nuts And Cotter Pin

19. Using the special tool, separate the tie-rod ends from the steering knuckles.
Fig. 210: Separating Tie-Rod Ends From Wheel Knuckles Using Special Tool (211-105)
2007 Ford Fusion SE
20. Disconnect the power steering cooler tube.
Fig. 211: Locating Power Steering Cooler Tube

21. Remove the nuts and separate the sway bar links from the struts.
Fig. 212: Locating Sway Bar Links And Nuts

22. Remove the lower ball joint nuts.
Fig. 213: Locating Lower Ball Joint Nuts
2007 Ford Fusion SE
CAUTION: When the lower ball joint is separated from the wheel knuckle, the
lower arm may strike the outer constant velocity (CV) joint boot with
enough force to damage the boot clamp. This will result in a loss of
grease from the outer CV joint. Place a block of wood, or similar item,
between the lower arm and the outer CV joint to prevent the lower
arm from striking the outer CV joint.
NOTE: Once pressure is applied to the ball joint with the special tool, it may be
necessary to tap the wheel knuckle at the ball joint area to separate the
ball joint from the wheel knuckle.
23. Using the special tools, separate the lower ball joints from the lower control arms.
Fig. 214: Identifying Special Tools (204-592/1, 204-592)

24. Remove the through bolts from the lower control arms.
Fig. 215: Locating Lower Control Arms Through Bolt

2007 Ford Fusion SE
25. Position the special tool under the subframe assembly.
Fig. 216: Positioning Special Tool (014-00765) Under Subframe Assembly

26. Remove the subframe bracket-to-body bolts.
Fig. 217: Locating Subframe Bracket-To-Body Bolts

27. Remove the subframe nuts and the subframe brackets.
Fig. 218: Locating Subframe Nuts
2007 Ford Fusion SE
28. Remove the front subframe nuts.
Fig. 219: Locating Front Subframe Nuts

29. Lower the subframe assembly from the vehicle.

30. Remove the engine oil pan drain plug and drain the engine oil.
l Install the drain plug and tighten to 28 Nm (21 lb-ft).
Fig. 220: Locating Engine Oil Pan Drain Plug

31. Remove the oil filter element. For additional information, refer to Engine Lubrication Components -
Exploded View and Oil Filter Element.
2007 Ford Fusion SE
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE
AIR DISTRIBUTION AND FILTERING - 2.3L .
CABLES .
35. Remove the nut and disconnect the wire from the battery cable.
Fig. 222: Locating Battery Cable And Nut

36. Disconnect the 2 engine wiring harness electrical connectors.
2007 Ford Fusion SE
Fig. 223: Locating Engine Wiring Harness Electrical Connectors

37. Remove the bolt and the ground wire.
Fig. 224: Locating Ground Wire And Bolt

38. Disconnect the powertrain control module (PCM) electrical connector and the pin-type retainer.
Fig. 225: Locating Powertrain Control Module (PCM) Electrical Connector And Pin-Type Retainer
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM -
40. Disconnect the crankcase vent tube from the valve cover.
2007 Ford Fusion SE
Fig. 226: Locating Crankcase Vent Tube

Fig. 228: Locating Evaporative Emissions (EVAP) Tube From Intake Manifold
43. Detach the retaining clip and position the EVAP tube bundle aside.
2007 Ford Fusion SE
44. Disconnect the upper radiator and heater hoses from the coolant bypass.
Fig. 230: Locating Upper Radiator And Heater Hoses

45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from
the heater hose.
Fig. 231: Locating Block Heater Electrical Connector Harness Retaining Clips
46. Disconnect the heater hose inline connector.
2007 Ford Fusion SE
Fig. 232: Locating Heater Hose Inline Connector

47. Disconnect the transaxle control cable from the control lever.
l Detach the control cable from the bracket.
Fig. 233: Locating Transaxle Control Cable From Control Lever

48. Disconnect the transaxle cooler tubes.
Fig. 234: Locating Transaxle Cooler Tubes

49. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
2007 Ford Fusion SE
Fig. 235: Locating Radio Frequency Interference Capacitor, Ground Wire And Bolt
50. Detach the coolant vent hose retaining clip from the A/C tube.
Fig. 236: Locating Coolant Vent Hose Retaining Clip


52. Remove the 2 A/C tube bracket bolts.
2007 Ford Fusion SE
Fig. 238: Locating A/C Tube Bracket Bolts

53. Remove the 2 nuts and disconnect the A/C tubes.
Fig. 239: Locating A/C Tubes Nuts

54. Remove the nut and disconnect the A/C tube from the condenser.
Fig. 240: Locating A/C Tube To Condenser Nut

2007 Ford Fusion SE
Fig. 241: Locating Radio Frequency Interference Capacitor Bolt

56. Remove the retaining clip and disconnect the lower radiator hose.
Fig. 242: Removing Retaining Clip And Locating Lower Radiator Hose
57. Using a suitable tool, separate the LH halfshaft from the transaxle and support the halfshaft with a length
of mechanic's wire.
58. Remove the 2 RH halfshaft carrier bearing bracket bolts.
Fig. 243: Locating RH Halfshaft Carrier Bearing Bracket Bolts

59. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
2007 Ford Fusion SE
Fig. 244: Locating RH Halfshaft Into Transaxle

Fig. 245: Locating Bellhousing-To-Oil Pan Bolt

Fig. 246: Locating Oil Pan-To-Bellhousing Bolts

2007 Ford Fusion SE
Fig. 247: Locating AIR Pump Electrical Connector

Fig. 248: Locating AIR Pump Bolts

All vehicles
NOTE: Position a suitable block of wood under the transaxle.
64. Install the special tools onto the engine.

l Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
2007 Ford Fusion SE
Fig. 249: Identifying Special Tools (014-0001, 014-00765)

65. Remove the 2 transaxle mount bolts.
Fig. 250: Locating Transaxle Mount Bolts

66. Remove the bolt, 2 nuts and the engine mount bracket.
2007 Ford Fusion SE
Fig. 251: Locating Engine Mount Bracket Bolt And Nuts

67. Lower the engine and transaxle from the vehicle.

68. Remove the 2 nuts and disconnect the starter wires.
Fig. 252: Locating Starter Wire Nuts

69. Detach the 2 wiring harness retainers from the starter stud bolts.
70. Remove the 2 stud bolts and the starter.
Fig. 253: Locating Starter And Stud Bolts

71. Remove the 4 torque convertor nuts.
2007 Ford Fusion SE
Fig. 254: Locating Torque Converter Nuts

72. Remove the bolt and ground wire.
Fig. 255: Locating Ground Wire Bolt

73. Remove the nut and position the engine wiring harness bracket aside.
Fig. 256: Locating Engine Wiring Harness Bracket And Nut

74. Disconnect the transmission range (TR) sensor and primary control solenoid electrical connectors.
2007 Ford Fusion SE
Fig. 257: Locating Transmission Range (TR) Sensor And Primary Control Solenoid Electrical
Connectors
75. Disconnect the transaxle control electrical connectors.
Fig. 258: Locating Transaxle Control Electrical Connectors

76. Disconnect the turbine shaft speed (TSS) sensor electrical connector.
Fig. 259: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
77. Disconnect the output shaft speed (OSS) sensor electrical connector.
2007 Ford Fusion SE
Fig. 260: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
78. Disconnect the transaxle pressure switch electrical connector.
Fig. 261: Locating Transaxle Pressure Switch Electrical Connector

79. Install the special tools and remove the engine and transaxle from the powertrain lift table.
Fig. 262: Identifying Special Tools (014-00071, 303-D089)

80. Remove the bellhousing-to-engine retainers.

l Separate the engine and transaxle.
ENGINE - MANUAL TRANSAXLE
2007 Ford Fusion SE
Special Tools
Separator, Ball joint 205-592
Adapter for 204-592 204-592/1
Tie-Rod End Remover 211-105
Remover, Halfshaft 205-832
Slide Hammer 100-001
Remover, Halfshaft 205-243
303-D089 (D93P-6001-A3) or
Spreader Bar
equivalent
2007 Ford Fusion SE
303-D095 (D94L-6001-A) or
equivalent
AND LIFTING .
INFORMATION .
AND CABLES .
4. Recover the air conditioning system. For additional information, refer to CLIMATE CONTROL
5. Place the steering wheel in the straight ahead position and the ignition key in the OFF position.
6. Remove the 2 nuts and the steering joint cover.
2007 Ford Fusion SE

CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected

from the gear or damage to the clockspring can occur. If there is
evidence that the intermediate shaft has rotated, the clockspring
must be removed and recentered. For additional information, refer to
SUPPLEMENTAL RESTRAINT SYSTEM .
NOTE: Index the steering column shaft position to the steering gear for reference
7. Remove the bolt and disconnect the steering column shaft from the steering gear.
Fig. 264: Locating Steering Column Shaft Index Mark And Bolt
8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump.
l Route the PSP tube out the bottom of the engine compartment.

9. Drain the cooling system. For additional information, refer to ENGINE COOLING .
2007 Ford Fusion SE

11. Remove the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .
CAUTION: The steering gear-to-dash seal must be removed or it will be

damaged when lowering the subframe.
12. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger
compartment.

13. Remove the engine roll restrictor bolt.
2007 Ford Fusion SE
14. Remove the 4 screws and position the RH fender splash shield aside.

15. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.

16. Remove the 4 screws and position the LH fender splash shield aside.

17. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
2007 Ford Fusion SE

18. Remove the cotter pins and nuts from the tie-rod ends.

19. Using the special tool, separate the tie-rod ends from the steering knuckles.
Fig. 274: Separating Tie-Rod Ends From Wheel Knuckles Using Special Tool (211-105)
2007 Ford Fusion SE

21. Remove the nuts and separate the sway bar links from the struts.

22. Remove the lower ball joint nuts.
2007 Ford Fusion SE
CAUTION: When the lower ball joint is separated from the wheel knuckle, the
lower arm may strike the outer constant velocity (CV) joint boot with
enough force to damage the boot clamp. This will result in a loss of
grease from the outer CV joint. Place a block of wood, or similar item,
between the lower arm and the outer CV joint to prevent the lower
arm from striking the outer CV joint.
NOTE: Once pressure is applied to the ball joint with the special tool, it may be
necessary to tap the wheel knuckle at the ball joint area to separate the
ball joint from the wheel knuckle.
23. Using the special tools, separate the lower ball joints from the lower control arms.
Fig. 278: Identifying Special Tools (204-592/1, 204-592)

24. Remove the through bolts from the lower control arms.

2007 Ford Fusion SE
25. Position the special tool under the subframe assembly.

26. Remove the subframe bracket-to-body bolts.

27. Remove the rear subframe nuts and the subframe brackets.
2007 Ford Fusion SE
28. Remove the front subframe nuts.

29. Lower the subframe assembly from the vehicle.

30. Remove the engine oil pan drain plug and drain the engine oil.
l Install the drain plug and tighten to 26 Nm (19 lb-ft).
Fig. 284: Locating Engine Oil Pan Drain Plug

31. Remove the oil filter element. For additional information, refer to Engine Lubrication Components -
2007 Ford Fusion SE
33. Remove the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE
CABLES .
35. Remove the nut and disconnect the wire from the battery cable.

36. Disconnect the 2 engine wiring harness electrical connectors.
2007 Ford Fusion SE

37. Remove the bolt and the ground wire.

38. Disconnect the powertrain control module (PCM) electrical connector and pin-type retainer.
39. Disconnect the fuel supply tube from the fuel rail. For additional information, refer to FUEL SYSTEM -
40. Disconnect the crankcase vent tube from the valve cover.
2007 Ford Fusion SE

43. Detach the retaining clip and position the EVAP tube bundle aside.
2007 Ford Fusion SE
44. Disconnect the upper radiator and heater hoses from the coolant bypass.

45. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from
the heater hose.
46. Disconnect the heater hose inline connector.
2007 Ford Fusion SE

47. Remove the 2 clutch tube bracket bolts.
Fig. 297: Locating Clutch Tube Bracket Bolts

Fig. 298: Locating Clutch Slave Cylinder Bolts

49. Disconnect the transaxle control cables from the control levers.
l Detach the control cables from the bracket.
2007 Ford Fusion SE
Fig. 299: Locating Control Cables


51. Remove the bolt and position the radio frequency interference capacitor and ground wire aside.
52. Detach the coolant vent hose retaining clip from the A/C tube.
2007 Ford Fusion SE

53. Remove the 2 A/C tube bracket bolts.

54. Remove the 2 nuts and disconnect the A/C tubes.

55. Remove the nut and disconnect the A/C tube from the condenser.
2007 Ford Fusion SE


57. Remove the retaining clip and disconnect the lower radiator hose.
Fig. 307: Removing Retaining Clip And Locating Lower Radiator Hose
58. Using the special tools, separate the LH halfshaft from the transaxle and support the halfshaft with a
length of mechanic's wire.
2007 Ford Fusion SE
Fig. 308: Identifying Special Tools (100-001, 205-243 And 205-832)

59. Remove the 2 RH halfshaft carrier bearing bracket bolts.

60. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.

2007 Ford Fusion SE



l Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
2007 Ford Fusion SE

64. Remove the 2 transaxle mount bolts.

65. Remove the bolt, 2 nuts and the motor mount bracket.
2007 Ford Fusion SE

66. Lower the engine and transaxle from the vehicle.

67. Remove the 2 nuts and disconnect the starter wires.

68. Detach the 2 wiring harness retainers from the starter stud bolts.
69. Remove the 2 bolts and the starter.

70. Remove the bolt and ground wire.
2007 Ford Fusion SE

71. Remove the nut and position the engine wiring harness bracket aside.

72. Disconnect the backup lamp electrical connector.
Fig. 320: Locating Backup Lamp Electrical Connector

73. Disconnect the vehicle speed sensor (VSS) electrical connector.
2007 Ford Fusion SE
Fig. 321: Locating Vehicle Speed Sensor (VSS) Electrical Connector

74. Install the special tools and remove the engine and transaxle from the powertrain lift table.
Fig. 322: Identifying Special Tools (014-00071, 303-D089)

75. Remove the bellhousing-to-engine retainers.

l Separate the engine and transaxle.
DISASSEMBLY
ENGINE
Special Tools
Engine Stand 014-00232 or equivalent
2007 Ford Fusion SE

205-126 (T78P-4851-A)
Flange
Adapter for 205-126 (205-072-02)
occur.

surfaces that enters the oil passages, coolant passages or the oil pan, can
CAUTION: Due to the precision fit and timing of the balancer shaft assembly, it
2007 Ford Fusion SE
cannot be removed from the engine block.
NOTE: For additional information, refer to the exploded views under the Engine.
build engines.
Vehicles with manual transaxle
WARNING: The clutch disc and clutch pressure plate are heavy and may fall if
not held when the bolts are removed. Failure to follow these
CAUTION: Loosen the 6 bolts evenly to prevent pressure plate damage.
1. Remove the 6 bolts, clutch pressure plate and clutch disc.
Fig. 323: Locating Clutch Pressure Plate Bolts

2. Remove the starter motor isolator.
2007 Ford Fusion SE
Fig. 324: Locating Starter Motor Isolator

3. Remove the 6 bolts and the flywheel.
Fig. 325: Locating Flywheel Bolts

Vehicles with automatic transaxle
4. Remove the 6 bolts and the flexplate.
Fig. 326: Locating Flexplate Bolts

All vehicles
5. Mount the engine on a suitable stand.

6. Using the hex feature, rotate the accessory drive belt tensioner clockwise and remove the accessory drive
belt from the coolant pump pulley.
2007 Ford Fusion SE
Fig. 327: Rotating Accessory Drive Belt Tensioner Clockwise

7. Remove the accessory drive belt from the engine.

8. Remove the 2 bolts and the tensioner.
Fig. 328: Locating Accessory Drive Belt Tensioner Bolts

9. Disconnect the power steering pressure (PSP) switch electrical connector.
Fig. 329: Locating Power Steering Pressure (PSP) Switch Electrical Connector
10. Remove the 2 upper power steering pump bolts.
2007 Ford Fusion SE
Fig. 330: Locating Upper Power Steering Pump Bolts

11. Remove the lower bolt and the power steering pump.
Fig. 331: Locating Power Steering Pump And Lower Bolt

12. Disconnect the knock sensor (KS) electrical connector and the 2 harness pin-type retainers.
Fig. 332: Locating Knock Sensor (KS) Electrical Connector And Harness Pin-Type Retainers
13. Disconnect the lower radiator and heater hoses from the thermostat housing.
l Detach the radiator hose retainer clip from the intake manifold.
2007 Ford Fusion SE
Fig. 333: Locating Lower Radiator And Heater Hoses From Thermostat Housing
14. Disconnect the coolant hose from the throttle body and remove the hose from the engine.
Fig. 334: Locating Coolant Hose

15. Disconnect the A/C compressor electrical connector.
Fig. 335: Locating A/C Compressor Electrical Connector

16. Remove the bolt and the A/C manifold.
2007 Ford Fusion SE
Fig. 336: Locating A/C Manifold And Bolt

17. Remove the 3 bolts and the A/C compressor.
Fig. 337: Locating A/C Compressor Bolts

18. Remove the 3 bolts and the coolant pump pulley.
Fig. 338: Locating Coolant Pump Pulley Bolts

19. Remove the 3 bolts and the coolant pump.

l Remove and discard the O-ring seal.
2007 Ford Fusion SE
Fig. 339: Locating Coolant Pump Bolts

20. Remove the bolt and the accessory drive belt idler pulley.
Fig. 340: Locating Accessory Drive Belt Idler Pulley Bolt

21. Disconnect the crankshaft position (CKP) sensor electrical connector and harness pin-type retainer.
Fig. 341: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Harness Pin-Type
Retainer
NOTE: Whenever the CKP sensor is removed, a new one must be installed, using
the alignment tool supplied with the new part.
2007 Ford Fusion SE
22. Remove the 2 bolts and the CKP sensor.

l Discard the CKP sensor.
Fig. 342: Locating CKP Sensor Bolts

23. Remove the 2 nuts and the generator splash shield.
Fig. 343: Locating Generator Splash Shield And Nuts

24. Pull back the rubber boot and remove the nut.
l Disconnect the generator electrical connections and pin-type retainer.
2007 Ford Fusion SE
Fig. 344: Locating Pin-Type Retainer And Generator Electrical Connections

25. Remove the bolt, 2 stud bolts and the generator.
Fig. 345: Locating Generator Bolt And Stud Bolts
2007 Ford Fusion SE
26. Disconnect the secondary air injection (AIR) hose from the catalytic converter.
Fig. 346: Locating Secondary AIR Injection (AIR) Hose

27. Disconnect the AIR valve vacuum supply tube from the intake manifold.
Fig. 347: Locating AIR Valve Vacuum Supply Tube

28. Disconnect the AIR valve electrical connector.
Fig. 348: Locating AIR Valve Electrical Connector

2007 Ford Fusion SE
29. Remove the 2 bolts and the AIR valve, hoses and pump assembly from the engine.
Fig. 349: Locating Pump Assembly Bolts

All vehicles
NOTE: Vehicles equipped with AIR have 2 catalyst monitor sensors (CMS).
30. Disconnect the CMS electrical connector(s).
Fig. 350: Locating CMS Electrical Connector

31. Disconnect the heated oxygen sensor (HO2S) electrical connector.
Fig. 351: Locating Heated Oxygen Sensor (HO2S) Electrical Connector
2007 Ford Fusion SE
32. Remove the wiring harness bracket from the valve cover stud.
Fig. 352: Locating Wiring Harness Bracket

33. Detach the wiring harness retainer from the valve cover stud.
Fig. 353: Locating Wiring Harness Retainer

NOTE: Vehicles equipped with AIR do not require removal of the heat shield.
34. Remove the 6 screws and the heat shield.
2007 Ford Fusion SE
Fig. 354: Locating Heat Shield Screws

35. Remove the 2 catalytic converter bracket bolts.
Fig. 355: Locating Catalytic Converter Bracket Bolts

36. Remove the 7 nuts, catalytic converter, gasket and the 7 studs.
l Discard the nuts, gasket and the studs.
2007 Ford Fusion SE
Fig. 356: Locating Nuts, Catalytic Converter, Gasket And Studs

37. If equipped, disconnect the block heater electrical connector.
Fig. 357: Locating Block Heater Electrical Connector

38. If equipped, remove the block heater.
Fig. 358: Locating Block Heater

39. Remove the 2 bolts and the catalytic converter bracket.
2007 Ford Fusion SE

40. Disconnect the coolant temperature sender electrical connector.
Fig. 360: Locating Coolant Temperature Sender Electrical Connector

41. Disconnect the exhaust gas recirculation (EGR) coolant hose and electrical connector.
Fig. 361: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
2007 Ford Fusion SE
Fig. 362: Locating Oil Pressure Sender Electrical Connector

43. Disconnect the manifold actual pressure (MAP) sensor electrical connector.
Fig. 363: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
44. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
Fig. 364: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
45. Disconnect the 2 swirl control valve electrical connectors.
2007 Ford Fusion SE
Fig. 365: Locating Swirl Control Valve Electrical Connectors

46. Detach the 2 wiring harness pin-type retainers from the intake manifold.
Fig. 366: Locating Wiring Harness Pin-Type Retainers From Intake Manifold
47. Disconnect the electronic throttle body electrical connector.
Fig. 367: Locating Electronic Throttle Body Electrical Connector

48. Remove the 8 bolts and position the intake manifold aside to access the crankcase vent hose clamp and
the EGR tube.
l Discard the gaskets.
2007 Ford Fusion SE
Fig. 368: Locating Intake Manifold Bolts

49. Disconnect the positive crankcase ventilation (PCV) hose and remove the intake manifold.
Fig. 369: Locating Positive Crankcase Ventilation (PCV) Hose

50. Remove the EGR tube.
Fig. 370: Locating Exhaust Gas Recirculation (EGR) Tube

51. Remove the 3 bolts and the thermostat housing.
2007 Ford Fusion SE
Fig. 371: Locating Thermostat Housing Bolts

52. Disconnect the bypass hose from the cylinder block nipple.
Fig. 372: Locating Bypass Hose From Cylinder Block Nipple

53. Disconnect the bypass hose from the coolant outlet and remove the bypass hose from the engine.
Fig. 373: Locating Bypass Hose To Coolant Outlet

54. Remove the bolt and the KS.
2007 Ford Fusion SE
Fig. 374: Locating Knock Sensor Bolt

55. Remove the 8 bolts and the crankcase vent oil separator.
Fig. 375: Locating Crankcase Vent Oil Separator And Bolts

56. Remove and discard the engine oil filter.

57. Remove the 4 bolts and the oil filter adapter.
Fig. 376: Locating Oil Filter Adapter And Bolts

58. Disconnect the camshaft position (CMP) sensor electrical connector.
2007 Ford Fusion SE
Fig. 377: Locating Camshaft Position (CMP) Sensor Electrical Connector

59. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.
Fig. 378: Locating Variable Camshaft Timing (VCT) Solenoid Electrical Connector
60. Disconnect the 4 coil-on-plug electrical connectors.
Fig. 379: Locating Coil-On-Plug Electrical Connectors

61. Pull back the boot and disconnect the cylinder head temperature (CHT) sensor electrical connector.
2007 Ford Fusion SE
Fig. 380: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector And Boot
62. Detach the 2 pin-type harness retainers and remove the fuel supply rail insulator.
Fig. 381: Locating Pin-Type Harness Retainers And Remove Fuel Supply Rail Insulator
63. Disconnect the 4 fuel injector electrical connectors.
Fig. 382: Locating Fuel Injector Electrical Connectors

NOTE: Typical wiring harness retainers shown.
64. Detach the remaining wiring harness retainers and remove the wiring harness from the engine.
2007 Ford Fusion SE
Fig. 383: Locating Wiring Harness Retainers

65. Remove the 2 bolts and the fuel rail and injector assembly.
Fig. 384: Locating Fuel Rail And Injector Assembly Bolts

66. Remove the 4 bolts and the 4 coil-on-plug assemblies.
Fig. 385: Locating Coil-On-Plug Assemblies And Bolts

67. Remove the oil level indicator.
2007 Ford Fusion SE

68. Loosen the 14 retainers and remove the valve cover.

l Discard the gaskets.
Fig. 387: Locating Valve Cover Retainers

CAUTION: Failure to position the No. 1 position at top dead center (TDC) can
2007 Ford Fusion SE
CAUTION: The special tool 303-465 is for camshaft alignment only. Using this to
prevent engine rotation can result in engine damage.


position during disassembly.
2007 Ford Fusion SE

Fig. 392: Assembling Special Tools (205-126 And 205-072-02)
2007 Ford Fusion SE
CAUTION: The crankshaft must remain in the TDC position during removal of
bolt should be removed using an air impact wrench (1/2-in drive
minimum).
CAUTION: If the crankshaft sprocket diamond washer comes off with the
crankshaft pulley, it must be installed back onto the crankshaft.
74. Using the special tools and an air impact wrench, remove the crankshaft pulley.
l Remove and discard the crankshaft pulley bolt and washer.
l Remove the crankshaft pulley.
Fig. 393: Locating Crankshaft Pulley Bolt And Special Tools (205-126, 205-072-02)
75. Using the special tool, remove the crankshaft front oil seal.
Fig. 394: Removing Crankshaft Front Oil Seal Using Special Tool (303-409)
2007 Ford Fusion SE
76. Remove the 22 bolts and the engine front cover.
Fig. 395: Locating Engine Front Cover Bolts

77. Remove the timing chain tensioner.

1. Compress the timing chain tensioner and insert a paper clip into the hole to retain the tensioner.
2. Remove the 2 bolts and timing chain tensioner.
Fig. 396: Locating Timing Chain Tensioner Bolt

78. Remove the RH timing chain guide.
2007 Ford Fusion SE

79. Remove the timing chain.

80. Remove the 2 bolts and the LH timing chain guide.

2007 Ford Fusion SE
sprocket.
Fig. 400: Locating Bolt And Exhaust Camshaft Sprocket

82. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the intake camshaft
sprocket.
Fig. 401: Locating Intake Camshaft Phaser And Sprocket Bolt

83. Remove the oil pump drive chain tensioner and guide.
2. Remove the 2 shoulder bolts and the tensioner.
3. Remove the 2 shoulder bolts and the guide.
2007 Ford Fusion SE
Fig. 402: Locating Tensioner Shoulder Bolts, Tensioner Spring And Guide
Late build vehicles
84. Remove the oil pump drive chain tensioner.

2. Remove the tensioner and the 2 shoulder bolts.
Fig. 403: Locating Shoulder Bolts & Tensioner

All vehicles
NOTE: Remove the crankshaft sprocket diamond washers located in front of and
behind the crankshaft sprocket.
NOTE: The oil pump chain sprocket must be held in place.
85. Remove the oil pump chain and sprockets.

1. Remove the bolt.
2. Remove the chain and sprockets.
2007 Ford Fusion SE
Fig. 404: Identifying Chain & Sprockets

86. Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.

87. Remove the bolt and the VCT solenoid.
Fig. 406: Locating Variable Camshaft Timing (VCT) Solenoid And Bolt

2007 Ford Fusion SE

positions.
3.650 mm.
90. Remove the cylinder head.
l Remove and discard the 10 cylinder head bolts.
l Remove the cylinder head.
l Remove and discard the cylinder head gasket.
Fig. 408: Locating Cylinder Head Bolts

2007 Ford Fusion SE
91. Remove the 2 cylinder head alignment dowels.
Fig. 409: Identifying Cylinder Head Alignment Dowels

Fig. 410: Locating Oil Pan Bolts

93. Remove the 6 bolts and the rear crankshaft seal.
Fig. 411: Locating Rear Crankshaft Seal Bolts

94. Remove the 2 bolts, oil pump pickup tube and gasket.
2007 Ford Fusion SE
Fig. 412: Locating Oil Pump Pickup Tube Bolts

95. Remove the 4 bolts and the oil pump.
Fig. 413: Locating Oil Pump Bolts

96. Make sure the Crankshaft TDC Timing Peg is still installed and the engine is still at Top Dead Center
(TDC).
l Rotate the crankshaft slowly clockwise until the crankshaft balance weight is up against the
Crankshaft TDC Timing Peg.
2007 Ford Fusion SE
97. Mark the balancer unit and shafts on the top for reference that the balancer unit is at TDC .
Remove the 4 bolts and the balancer unit.
2007 Ford Fusion SE
Fig. 416: Locating Balancer Unit Bolts
100. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.
NOTE: Clearly mark the connecting rods, connecting rod caps and connecting
101. rod bearings in numerical order for correct orientation for reassembly.
Remove the connecting rod cap bolts and cap.
2007 Ford Fusion SE
Fig. 418: Locating Connecting Rod Cap Bolts
NOTE: Do not scratch the cylinder walls or crankshaft journals with the
102. connecting rod.
Using the Connecting Rod Installer, remove the piston/rod assembly from the engine block.
l Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
Fig. 419: Identifying Connecting Rod Installer
103. Remove the bolts in the sequence shown.

l Remove the main bearing beam.
l Discard the bolts.
2007 Ford Fusion SE
Fig. 420: Identifying Crankshaft Cap Bolts Removing Sequence
104. Remove the crankshaft from the engine block.
Fig. 421: Locating Crankshaft
NOTE: If the main bearings are being reused, mark them in order for correct
105. orientation and reassembly.
Remove the main bearings from the main bearing beam.
Fig. 422: Locating Main Bearings
NOTE: If the main bearings are being reused, mark them in order for correct
106. orientation and reassembly.
NOTE: The center bulkhead has the thrust bearing.
Remove the main bearings from the cylinder block.
2007 Ford Fusion SE
Fig. 423: Locating Main Bearings
NOTE: If the oil squirters are being reused, mark them in order for correct
107. location during reassembly.
NOTE: The front bulkhead does not have an oil squirter.
Remove the 4 oil squirters.
Fig. 424: Locating Oil Squirters
108. Inspect the cylinder block, main bearing beam, pistons and connecting rods. For additional information,
refer to ENGINE SYSTEM - GENERAL INFORMATION .
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

CYLINDER HEAD
Special Tools
2007 Ford Fusion SE
Remover, Valve Stem Oil Seal 303-468 (T94P-6510-AH)
Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)
Slide Hammer 307-005 (T59L-100-B)
Material
Item Specification
Motor Oil
ESB-M1C93-B
XG-4 and/or XL-5
2007 Ford Fusion SE
Fig. 425: Exploded View Of Cylinder Head


1 W500015 Coolant outlet bolt (4 required)
2 8K556 Coolant outlet
3 8255 Coolant outlet gasket
Exhaust gas recirculation (EGR) valve
4 W500225
bolt (2 required)
5 9D475 EGR valve
6 9D476 EGR valve gasket
7 6G004 Cylinder head temperature (CHT) sensor
8 12405 Spark plug (4 required)
12 6517 Valve seal (16 required)
13 6505 Intake valve (8 required)
14 6507 Exhaust valve (8 required)
DISASSEMBLY
CAUTION: If the components are to be reinstalled, they must be installed in the same
2007 Ford Fusion SE
positions. Mark the components removed for locations.
1. Remove the 4 bolts and the coolant outlet.

2. Remove the 2 bolts and the exhaust gas recirculation (EGR) valve.
3. Remove and discard the cylinder head temperature (CHT) sensor.
CAUTION: Only use hand tools when removing or installing the spark plugs,
damage can occur to the cylinder head or spark plug.
4. Remove the spark plugs.
NOTE: Use a small screwdriver and grease to remove the valve collets.
5. Using the special tools, compress the valve springs and remove the valve collets, valve spring retainers
and the valve springs.

6. Inspect the components, if necessary. For additional information, refer to ENGINE SYSTEM -
7. Remove the valves.
8. Using the special tools, remove and discard the valve seals.
2007 Ford Fusion SE
Fig. 427: Removing Valve Seal Using Special Tools (307-005, 303-468)
9. Inspect the valves. For additional information, refer to ENGINE SYSTEM - GENERAL
INFORMATION . Install new parts, as necessary.
ASSEMBLY
NOTE: Coat the valve stems with clean engine oil.
1. Install the valves.
NOTE: Use the protector provided with the replacement kit to prevent damage to
the valve seals. Lubricate the valve stems and guides with clean engine
oil.
2. Using the special tool, install the valve seals.
Fig. 428: Installing Valve Seal Using Special Tool (303-470)

NOTE: Check the seating of the valve collets.
3. Using the special tools, install the valve springs.

l Insert the valve springs and the valve spring retainers.
l Compress the valve springs and install the valve collets, using grease and a small screwdriver.
2007 Ford Fusion SE

CAUTION: Only use hand tools when removing or installing the spark plugs,
damage can occur to the cylinder head or spark plug.
4. Install the spark plugs.

5. Install a new CHT sensor.

6. Install the EGR valve, using a new gasket.

7. Using a new gasket, install the coolant outlet and bolts.

ASSEMBLY
ENGINE BLOCK
For engine block, crankshaft and piston assembly installation procedures, refer to ENGINE BLOCK - 2.3L .
ENGINE (EXCEPT BLOCK)
Special Tools
303-D089 (D93P-6001-A3) or
Spreader Bar
equivalent
2007 Ford Fusion SE

205-126 (T78P-4851-A)
Flange
Adapter for 205-126 (205-072-02)
Installer, Crankshaft Rear Main

303-328 (T88P-6701-B1)
Oil Seal
Aligner, Clutch Disc 308-006 (T71P-7137-H)
Material
2007 Ford Fusion SE
Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor
Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super WSS-M2C930-A
Premium Motor Oil CXO-5W20-LSP12 (Canada); or
equivalent
WSE-M5B392-A
ZC-21
WSE-M4G323-A4
TA-30
Silicone Gasket Remover
-
ZC-30
Motorcraft Metal Surface Prep ZC-31
-
Silicone Brake Caliper Grease and Dielectric Compound
ESE-M1C171-A
XG-3-A
Motorcraft Premium Engine Coolant with Bittering
Agent (US); Motorcraft Premium Quality
Antifreeze/Coolant (Canada) ESE-M97B44-A
VC-5 (US); CXC-10 (Canada); or equivalent (green
color)
High Temperature 4x4 Front Axle and Wheel Bearing
Grease ESA-M1C198-A
E8TZ-19590-A
2007 Ford Fusion SE
Fig. 430: Exploded View Of Lower Engine Block (View 1)


1 6010 Cylinder block
2 6K318 Crankshaft rear oil seal and retainer
3 6477 Flywheel
4 6675 Oil pan
5 6622 Oil pump screen and pickup tube
6 8575 Thermostat assembly
7 6A785 Crankcase vent oil separator
8 6884 Oil filter adapter
9 6A636 Oil filter adapter gasket
2007 Ford Fusion SE
Fig. 431: Identifying Lower Engine Block Components (View 2)
ITEM DESCRIPTION
1 6161 Piston oil control spacer (4
required)
2 6150 Piston compression upper ring (4
required)
3 6152 Piston compression lower ring (4
required)
4 6159 Piston oil control upper segment
ring (4 required)
5 6159 Piston oil control lower segment
ring (4 required)
2007 Ford Fusion SE
6 6140 Piston pin retainer (8 required)

7 6135 Piston pin (4 required)
8 6200 Connecting rod (4 required)
9 6211 Connecting rod upper bearing (4
required)
10 6110 Piston (4 required)
11 6211 Connecting rod lower bearing (4
required)
12 6210 Connecting rod cap (4 required)
14 6333 Cylinder block crankshaft main
bearing (5 required)
15 6303 Crankshaft
16 6333 Crankshaft main bearing beam
bearing (5 required)
17 6F098 Main bearing beam
18 6K360 Balance shaft assembly
2007 Ford Fusion SE
Fig. 432: Exploded View Of Front Engine Block


1 6B209 Accessory drive belt tensioner
2 10300 Generator
3 8501 Coolant pump and pulley
4 6C315 Crankshaft position (CKP) sensor
5 6A340 Crankshaft pulley bolt
6 6316 Crankshaft pulley
7 6C348 Idler pulley
8 6C348 Idler pulley (without A/C only)
10 6019 Engine front cover
2007 Ford Fusion SE
11 6K254 Timing chain tensioner

12 6K255 Timing chain tensioner arm
13 6268 Timing chain
14 6K297 Timing chain guide
15 6C271 Oil pump chain tensioner
16 6M256 Oil pump chain guide (early build)
17 6A895 Oil pump chain
18 6652 Oil pump drive gear
19 6378 Diamond washer
20 6306 Crankshaft sprocket
21 6378 Diamond washer
22 6600 Oil pump
2007 Ford Fusion SE
Fig. 433: Exploded View Of Cylinder Head


1 12A366 Coil-on-plug assembly (4 required)
2 6766 Oil filler cap
3 12K073 Camshaft position (CMP) sensor
2007 Ford Fusion SE
4 6M293 Valve cover

5 6M293 Valve cover gasket
6 6M280 Variable camshaft timing (VCT) solenoid
7 6A284 Camshaft bearing caps (9 required)
8 6A258 Camshaft bearing cap
9 6A272 Camshaft (exhaust)
10 6A271 Camshaft (intake)
11 6C251 Camshaft sprocket
12 6C525 VCT actuator
17 6A517 Valve stem seal (16 required)
18 6G004 Cylinder head temperature (CHT) sensor
19 12405 Spark plug (4 required)
20 6065 Cylinder head bolt (10 required)
22 6505 Exhaust valve (8 required)
23 6507 Intake valve (8 required)
24 6051 Head gasket
Catalytic converter gasket (with
26 9448
secondary air injection)
Catalytic converter (with secondary air
27 5E211
injection)
28 - Heat shield (with secondary air injection)
Catalytic converter gasket (without
29 9448
secondary air injection)
Catalytic converter (without secondary
30 5E211
air injection)
Heat shield (without secondary air
31 -
injection)
2007 Ford Fusion SE
Fig. 434: Exploded View Of Intake Manifold


1 8K556 Coolant outlet
2 9D475 Exhaust gas recirculation (EGR) valve
3 9F991 Throttle body
4 6051 Cylinder head gasket
6 12A699 Knock sensor (KS)
7 9424 Intake manifold
8 9439 Intake manifold gasket
9 8A582 Coolant hose
2007 Ford Fusion SE
11 9F593 Fuel injector (4 required)

12 9H487 Fuel rail
13 - Fuel rail insulator
occur.

surfaces that enters the oil passages, coolant passages or the oil pan, can
build engines.
All vehicles
NOTE: If the oil squirters are being reused, they must be installed in the same
1. location as marked during disassembly.
NOTE: The front bulkhead does not have an oil squirter.
Install the 4 oil squirters.
2007 Ford Fusion SE
Fig. 435: Locating Oil Squirters
2. Measure each of the crankshaft main bearing journal diameters in at least 2 directions and record the
smallest diameter for each journal.
Fig. 436: Identifying Measuring Directions Of Crankshaft Main Bearing Journal Diameter
3. Position the main bearing beam in the engine block with the main bearing beam mounted flush with the
rear face of the engine block.
Fig. 437: Locating Main Bearing Beam
4. Using the original main bearing beam bolts, install and tighten the 10 main bearing beam bolts.
l Tighten the bolts in the sequence shown in 3 stages.
2007 Ford Fusion SE

l Stage 3: Tighten an additional 90 degrees.
Fig. 438: Identifying Main Bearing Beam Bolts Tightening Sequence
5. Measure each crankshaft block main bearing bore diameter.

l Remove the bolts and the main bearing beam.
l Discard the main bearing beam bolts.
Fig. 439: Identifying Crankshaft Block Main Bearing Bore Diameter
6. Using the chart, select the crankshaft main bearings.
2007 Ford Fusion SE
Fig. 440: Crankshaft Main Bearings Chart
NOTE: The rod cap installation must keep the same orientation as marked during
7. disassembly or engine damage may occur.
Using the original connecting rod cap bolts, install the connecting caps and bolts.
Tighten the bolts in 2 stages.

l
8. Measure the connecting rod large end bore in 2 directions. Record the smallest measurement for each
connecting rod.
l Remove the bolts and the connecting rod cap.
l Discard the connecting rod cap bolts.
2007 Ford Fusion SE
Fig. 441: Identifying Connecting Rod Large End Bore Measuring Directions
9. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. Record
the smallest measurement for each connecting rod journal.
Fig. 442: Identifying Measuring Directions Of Crankshaft Connecting Rod Bearing Journal
Diameters
10. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
2007 Ford Fusion SE
Fig. 443: Connecting Rod Bearings Chart
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of
chips, dirt, paint and foreign material. Also, make sure the coolant and oil
11. passages are clear.
NOTE: If reusing the crankshaft main bearings, install them in their original
positions and orientation as noted during disassembly.
NOTE: The center bulkhead is the thrust bearing.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 5 crankshaft main
bearings in the cylinder block.
2007 Ford Fusion SE
Fig. 444: Locating Upper Crankshaft Main Bearings
NOTE: If reusing the crankshaft main bearings, install them in their original
12. positions and orientation as noted during disassembly.
Lubricate the crankshaft main bearings with clean engine oil and install the 5 crankshaft main bearings in
the main bearing beam.
Fig. 445: Locating Crankshaft Main Bearings
13. Lubricate journals on the crankshaft with clean engine oil.

14. Position the crankshaft in the cylinder block.
Fig. 446: Locating Crankshaft
15. Lubricate the 10 main bearing beam side fit surfaces (front 2 shown) with clean engine oil.
2007 Ford Fusion SE
Fig. 447: Locating Main Bearing Beam Side Fit Surfaces
16. Lubricate the crankshaft bearing journals on the main bearing beam with clean engine oil. Then position
the main bearing beam in the engine block with the main bearing beam mounted flush with the rear face
of the engine block.
Fig. 448: Locating Main Bearing Beam
NOTE: Lubricate the main bearing beam bolts threads and under the bolt heads
17. with clean engine oil.
NOTE: Position the crankshaft to the rear of the cylinder block, then position the
crankshaft to the front of the cylinder block before tightening the main
bearing beam bolts.
Install and tighten the 10 new main bearing beam bolts.
l Tighten the bolts in the sequence shown in 3 stages.

2007 Ford Fusion SE
Fig. 449: Identifying Main Bearing Beam Bolts Tightening Sequence
18. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
l Position the crankshaft to the rear of the cylinder block.
l Zero the Dial Indicator Gauge with Holding Fixture.
l Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
l Acceptable crankshaft end play is 0.22-0.43 mm (0.008-0.016 in). If the crankshaft end play
exceeds the specified range, install new parts as necessary.
Fig. 450: Measuring Crankshaft End Play
NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the
connecting rod. Push the piston down until the connecting rod bearing
19. seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire
cylinder bores with clean engine oil.
NOTE: Make sure the piston arrow on top is facing toward the front of the engine.
Using the Piston Ring Compressor and the Connecting Rod Installer, install the piston and connecting rod
assemblies.
l When installing the pistons and connecting rod assemblies, the oil ring gaps must be positioned 60
2007 Ford Fusion SE
degrees apart from each other and a minimum of 90 degrees from the expander gap.
l The position of the upper and lower compression ring gaps are not controlled for installation.
Fig. 451: Identifying Piston Ring Compressor And Connecting Rod Installer
NOTE: The rod cap installation must keep the same orientation as marked during
20. disassembly or engine damage may occur.
NOTE: Install connecting rod caps and bolts on the connecting rods for cylinders
1 and 4 first and tighten. Then rotate crankshaft 180 degrees and install
connecting rod caps and bolts on connecting rods for cylinders 2 and 3
and tighten.
NOTE: After installation of each connecting rod cap, rotate the crankshaft to
verify smooth operation.
Install the connecting rod caps and the new bolts.
l Tighten the bolts in 2 stages.

2007 Ford Fusion SE
Fig. 452: Locating Connecting Rod Cap Bolts
balance weight is up against the Crankshaft TDC Timing Peg. The engine is now at Top Dead Center
(TDC).
NOTE: The original adjustment shims must be installed in their original position.
NOTE: Confirm by visual inspection that there is no damage to the balancer unit
2007 Ford Fusion SE
gear and verify that the shaft turns smoothly. If there is any damage or
malfunction, replace the balancer unit.
Install the adjustment shims in their original position on the seat faces of the balancer unit.
23. With the balancer unit shaft marks in the TDC position, slowly install the balancer unit to the cylinder

2007 Ford Fusion SE
26. Rotate the crankshaft to confirm that there are no meshing problems between the balancer unit gear and
the crankshaft gear.
balance weight is up against the Crankshaft TDC Timing Peg.
l Remove the Crankshaft TDC Timing Peg.
2007 Ford Fusion SE
NOTE: Measure the backlash and verify that it is within specified range at all of
2007 Ford Fusion SE
l Backlash specifications are 0.005 to 0.101 mm (0.00019 to 0.0039 in).

l If the backlash exceeds the specified range, carry out the balance shaft backlash procedure. For
additional information, refer to the Balance Shaft Backlash procedure in this section.
WARNING: Failure to position the No. 1 piston at top dead center (TDC) can
29. Turn the crankshaft clockwise to position the No. 1 piston at TDC.

2007 Ford Fusion SE
position until the timing drive components and crankshaft pulley are
installed.

NOTE: Clean the oil pump and cylinder block mating surfaces with metal surface
cleaner.
32. Install the oil pump assembly. Tighten the 4 bolts in the sequence shown in 2 stages:
2007 Ford Fusion SE
Fig. 461: Identifying Oil Pump Bolts Tightening Sequence

33. Install a new gasket, oil pump pickup tube and the 2 bolts.
Fig. 462: Locating Oil Pump Pickup Tube Bolts

34. Using the special tool, install the crankshaft rear main oil seal.
Fig. 463: Positioning Crankshaft Rear Oil Seal Using Special Tool (303-328)
35. Tighten the 6 crankshaft rear main oil seal bolts in the sequence shown.
2007 Ford Fusion SE
Fig. 464: Identifying Tightening Sequence Of Crankshaft Rear Main Oil Seal Bolts
36. Clean and inspect all mating surfaces.
leakage.
37. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the oil pan.
l Position the oil pan onto the engine and install the 2 rear oil pan bolts finger-tight.

38. Using a suitable straight edge, align the front surface of the oil pan flush with the front surface of the
engine block.
2007 Ford Fusion SE
Fig. 466: Aligning Front Surface Of Oil Pan Flush With Front Surface Of Engine Block Using
Suitable Straightedge
39. Install the remaining oil pan bolts.

l Tighten in the sequence shown to 20 Nm (15 lb-ft).

40. Install the 2 cylinder head alignment dowels. Dowels must be fully seated in the cylinder block.
2007 Ford Fusion SE
Fig. 468: Identifying Cylinder Head Alignment Dowels

cause scratches and gouges that make leak paths. Use a plastic
scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings and cautions and follow all application
directions contained on the packaging of the silicone gasket remover
and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be
used to clean and prepare the surfaces.
41. Clean the cylinder head-to-cylinder block mating surface of both the cylinder head and the cylinder block.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket
remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any traces of oil or coolant, and
to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some
staining of the metal surfaces is normal.
2007 Ford Fusion SE
Fig. 469: Identifying Silicone Gasket And Sealant Location

43. Install a new head gasket.
Fig. 470: Identifying Head Gasket

NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New
cylinder head bolts must be installed.
NOTE: Lubricate the bolts with clean engine oil prior to installation.
44. Install 10 new cylinder head bolts. Tighten the bolts in the sequence shown in 5 stages:
l Stage 4: Turn 90 degrees.
l Stage 5: Turn an additional 90 degrees.
Fig. 471: Identifying Tightening Sequence Of Cylinder Head Bolts

NOTE: Coat the valve tappets with clean engine oil prior to installation.
2007 Ford Fusion SE
45. Install the valve tappets,
stages:
l Stage 1: Tighten the camshaft bearing cap bolts until finger tight.

47. Install the variable camshaft timing (VCT) solenoid and the bolt.
Fig. 473: Locating Variable Camshaft Timing (VCT) Solenoid And Bolt
2007 Ford Fusion SE
NOTE: Install a crankshaft sprocket diamond washer on both sides of the

crankshaft sprocket.
48. Install the crankshaft sprocket and crankshaft sprocket diamond washers.
l The crankshaft sprocket flange must be facing away from the engine block.
Fig. 474: Locating Washers, Oil Pump Chain & Sprockets

49. Install the oil pump drive chain, sprocket and bolt.
Fig. 475: Locating Oil Pump Chain, Sprocket & Bolt

Late build vehicles
50. Install the oil pump drive chain tensioner shoulder bolt.
2007 Ford Fusion SE
Fig. 476: Locating Oil Pump Chain Drive Tensioner Shoulder Bolt
51. Install the oil pump drive chain guide and the shoulder bolts.
Fig. 477: Locating Oil Pump Chain Guide & Shoulder Bolts
All vehicles
52. Install the oil pump drive chain tensioner and bolt. Hook the tensioner spring around the shoulder bolt.
Fig. 478: Locating Oil Pump Chain Tensioner And Bolt
2007 Ford Fusion SE

54. Install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
Fig. 480: Locating Camshaft Sprockets And Bolts

55. Install the timing chain guide and the 2 bolts.

2007 Ford Fusion SE

56. Install the timing chain.

57. Install the timing chain tensioner arm.

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet
assembly.
58. Using the edge of a vise, compress the timing chain tensioner plunger.
2007 Ford Fusion SE
Fig. 484: Using Edge Of A Vise To Compress Timing Chain Tensioner Plunger
59. Using a small pick, push back and hold the ratchet mechanism.
Fig. 485: Using A Small Pick To Push Back And Hold Ratchet Mechanism
60. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Fig. 486: Pushing Ratchet Arm Back Into Tensioner Housing

61. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and the plunger in
2007 Ford Fusion SE
Fig. 487: Installing Paper Clip Into Hole In Tensioner Housing To Hold Ratchet Assembly And
Plunger
62. Install the timing chain tensioner and the 2 bolts. Remove the paper clip to release the piston.
Fig. 488: Locating Timing Chain Tensioner Bolts And Paper Clip
63. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
Fig. 489: Identifying Camshafts Sprocket Bolts
2007 Ford Fusion SE
other abrasive means to clean sealing surfaces. These tools cause
scratches and gouges which make leak paths.
64. Clean and inspect the mounting surfaces of the engine and the front cover.
NOTE: The engine front cover must be installed and the bolts tightened within 4
minutes of applying the silicone gasket and sealant.
65. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas.
Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
Fig. 490: Locating Silicone Gasket

66. Install the engine front cover. Tighten the 22 bolts in the sequence shown, to the following specifications:
l Tighten the 8-mm bolts to 10 Nm (89 lb-in).
l Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
2007 Ford Fusion SE
Fig. 491: Identifying Engine Front Cover Bolts Tightening Sequence

67. Using the special tool, install a new crankshaft front oil seal.
CAUTION: Do not install the crankshaft pulley bolt at this time.
2007 Ford Fusion SE
NOTE: Apply clean engine oil on the seal area before installing.
68. Position the crankshaft pulley onto the crankshaft with the hole in the pulley at the 6 o'clock position.
Fig. 493: Locating Crankshaft Pulley & Hole

CAUTION: Only hand-tighten the 6 mm (0.23 in) bolt or damage to the front
cover can occur.
NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
front cover.
Fig. 494: Locating Crankshaft Pulley Bolt

2007 Ford Fusion SE
Fig. 495: Assembling Special Tools (205-126 And 205-072-02) And Hardened Washers
CAUTION: The crankshaft must remain in the TDC position during installation of
bolt should be installed using hand tools only.
CAUTION: Do not reuse the crankshaft pulley bolt.
71. Install a new crankshaft pulley bolt. Using the special tools to hold the crankshaft pulley in place, tighten
the crankshaft pulley bolt in 2 stages:
l Stage 2: Tighten an additional 90 degrees (1/4 turn).
2007 Ford Fusion SE
Fig. 496: Using Special Tools (205-126, 205-072-02) To Hold Crankshaft Pulley In Place


2007 Ford Fusion SE

75. Turn the crankshaft clockwise 1 and 3/4 turns.


77. Turn the crankshaft clockwise until the crankshaft contacts the special tool.
2007 Ford Fusion SE

78. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
l If it is not possible to install the bolt, the engine valve timing must be corrected.
79. Using the special tool, check the position of the camshafts.
l If it is not possible to install the special tool, the engine valve timing must be corrected.
2007 Ford Fusion SE


NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one
must be installed using the alignment tool supplied with the new part.
81. Install a new CKP sensor and the 2 bolts.

l Do not tighten the bolts at this time.
Fig. 505: Locating CKP Sensor

2007 Ford Fusion SE
NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not
available separately.
82. Adjust the CKP sensor with the alignment tool.

l Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
Fig. 506: Locating CKP Sensor Alignment Tool And Bolts

2007 Ford Fusion SE


cause scratches and gouges which make leak paths.
86. Clean the valve cover gasket surface with metal surface cleaner.
NOTE: The valve cover must be secured within 4 minutes of silicone gasket
application. If the valve cover is not secured within 4 minutes, the sealant
must be removed and the sealing area cleaned with metal surface cleaner.
Fig. 510: Applying Silicone Gasket And Sealant

88. Install the valve cover.

l Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
2007 Ford Fusion SE
Fig. 511: Identifying Valve Cover Bolts Tightening Sequence

NOTE: Make sure the notch on the oil level indicator is aligned with the V-shaped
boss on the valve cover and fully engaged into the valve cover.
89. Install the oil level indicator.

NOTE: Apply dielectric compound to the inside of the coil-on-plug boots.
90. Install the 4 coil-on-plug assemblies 4 bolts.

Fig. 513: Locating Coil-On-Plug Assemblies And Bolts
2007 Ford Fusion SE
CAUTION: Use O-ring seals that are made of special fuel-resistant material. Use
of ordinary O-rings can cause the fuel system to leak. Do not reuse
the O-ring seals.
91. Install new fuel injector O-rings.

l Separate the fuel injectors from the fuel rail.
l Remove and discard the fuel injector O-rings.
l Install new O-rings and lubricate with clean engine oil.
l Install the fuel injectors onto the fuel rail.
Fig. 514: Identifying Fuel Injector O-Ring Seals

92. Install the fuel rail and injector assembly and the 2 bolts.
Fig. 515: Locating Fuel Rail And Injector Assembly Bolts

NOTE: Typical wiring harness retainers shown.
93. Position the wiring harness on the engine and attach the wiring harness retainers.
2007 Ford Fusion SE
Fig. 516: Locating Wiring Harness Retainers

94. Connect the 4 fuel injector electrical connectors.
Fig. 517: Locating Fuel Injector Electrical Connectors

95. Install the fuel supply rail insulator and attach the 2 pin-type harness retainers.
Fig. 518: Locating Pin-Type Harness Retainers And Remove Fuel Supply Rail Insulator
96. Connect the cylinder head temperature (CHT) sensor electrical connector and install the boot.
2007 Ford Fusion SE
Fig. 519: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector And Boot
97. Connect the 4 coil-on-plug electrical connectors.
Fig. 520: Locating Coil-On-Plug Electrical Connectors

98. Connect the VCT solenoid electrical connector.
Fig. 521: Locating Variable Camshaft Timing (VCT) Solenoid Electrical Connector
99. Connect the camshaft position (CMP) sensor electrical connector.
2007 Ford Fusion SE
Fig. 522: Locating Camshaft Position (CMP) Sensor Electrical Connector

100. Install a new gasket, the oil filter adapter and the 4 bolts.
Fig. 523: Locating Oil Filter Adapter And Bolts

NOTE: Lubricate the oil filter seal (spin on filter type) or oil filter cup O-ring seal
(replaceable filter element type) with clean engine oil.
101. Install a new engine oil filter.

l Tighten the oil filter (spin on filter type) to 18 Nm (13 lb-ft).
l Tighten the oil filter cup (replaceable filter element type) to 33 Nm (24 lb-ft).
102. Using a new gasket, install the crankcase vent oil separator and the bolts.
2007 Ford Fusion SE
Fig. 524: Locating Crankcase Vent Oil Separator And Bolts

NOTE: The knock sensor (KS) must not touch the crankcase vent oil separator.
103. Install the KS and the bolt.

Fig. 525: Locating Knock Sensor Bolt

104. Position the bypass hose on the engine and connect the bypass hose to the coolant outlet.
Fig. 526: Locating Bypass Hose To Coolant Outlet

105. Connect the bypass hose to the cylinder block nipple.
2007 Ford Fusion SE
Fig. 527: Locating Bypass Hose From Cylinder Block Nipple

NOTE: Clean and inspect the thermostat housing gasket. Install a new gasket, if
necessary.
106. Install the thermostat housing and the 3 bolts.

Fig. 528: Locating Thermostat Housing Bolts

107. Install the EGR tube.

Fig. 529: Locating Exhaust Gas Recirculation (EGR) Tube

2007 Ford Fusion SE
108. Position the intake manifold and connect the positive crankcase ventilation hose.
Fig. 530: Locating Positive Crankcase Ventilation (PCV) Hose

109. Install new gaskets, the intake manifold and the 8 bolts.
l Tighten the bolts to 18 Nm (13 lb-ft).
Fig. 531: Locating Intake Manifold Bolts

110. Connect the electronic throttle body electrical connector.
Fig. 532: Locating Electronic Throttle Body Electrical Connector

111. Attach the 2 wiring harness pin-type retainers to the intake manifold.
2007 Ford Fusion SE
Fig. 533: Locating Wiring Harness Pin-Type Retainers From Intake Manifold
112. Connect the 2 swirl control valve electrical connectors.
Fig. 534: Locating Swirl Control Valve Electrical Connectors

113. Connect the intake manifold runner control (IMRC) actuator electrical connector.
Fig. 535: Locating Intake Manifold Runner Control (IMRC) Actuator Electrical Connector
114. Connect the temperature manifold actual pressure (MAP) sensor electrical connector.
2007 Ford Fusion SE
Fig. 536: Locating Manifold Actual Pressure (MAP) Sensor Electrical Connector
115. Connect the oil pressure sender electrical connector.
Fig. 537: Locating Oil Pressure Sender Electrical Connector

116. Connect the exhaust gas recirculation (EGR) coolant hose and electrical connector.
Fig. 538: Locating Exhaust Gas Recirculation (EGR) Coolant Hose And Electrical Connector
117. Connect the coolant temperature sender electrical connector.
2007 Ford Fusion SE
Fig. 539: Locating Coolant Temperature Sender Electrical Connector

118. Install the catalytic converter bracket and the 2 bolts.


119. If equipped, install the block heater.

Fig. 541: Locating Block Heater

120. If equipped, connect the block heater electrical connector.
2007 Ford Fusion SE
Fig. 542: Locating Block Heater Electrical Connector

121. Install 7 new catalytic converter studs in the cylinder head.

CAUTION: Failure to tighten the catalytic converter nuts to specification before

installing the converter bracket bolts will cause the converter to
develop an exhaust leak.
CAUTION: Failure to tighten the catalytic converter nuts to specification a

second time will cause the converter to develop an exhaust leak.
NOTE: Make sure to tighten the nuts in the sequence in 2 stages.
122. Install a new gasket, the catalytic converter and 7 new nuts. Tighten the nuts in 2 stages in the sequence
shown.
Fig. 543: Identifying Catalytic Converter Manifold Nuts Tightening Sequence

123. Install the 2 catalytic converter bracket bolts.

2007 Ford Fusion SE

NOTE: Vehicles equipped with AIR did not require removal of the heat shield.
124. Install the heat shield and the 6 screws.

Fig. 545: Locating Heat Shield Screws

125. Attach the wiring harness retainer to the valve cover stud.
2007 Ford Fusion SE
Fig. 546: Locating Wiring Harness Retainer

126. Attach the wiring harness bracket to the valve cover stud.
Fig. 547: Locating Wiring Harness Bracket

127. Connect the heated oxygen sensor (HO2S) electrical connector.
Fig. 548: Locating Heated Oxygen Sensor (HO2S) Electrical Connector

NOTE: Vehicles equipped with secondary air injection (AIR) have 2 catalyst
monitor sensors (CMS).
128. Connect the CMS electrical connector(s).
2007 Ford Fusion SE
Fig. 549: Locating CMS Electrical Connector

129. Position the AIR valve, hoses and pump assembly onto the engine and install the 2 bolts.
Fig. 550: Locating Pump Assembly Bolts

130. Connect the AIR valve electrical connector.
Fig. 551: Locating AIR Valve Electrical Connector

131. Connect the AIR valve vacuum supply tube to the intake manifold.
2007 Ford Fusion SE
Fig. 552: Locating AIR Valve Vacuum Supply Tube

132. Connect the AIR hose to the catalytic converter.
Fig. 553: Locating Secondary AIR Injection (AIR) Hose

All vehicles
133. Install the generator, bolt and 2 stud bolts.

2007 Ford Fusion SE
Fig. 554: Locating Generator Bolt And Stud Bolts

134. Connect the pin-type retainer, generator electrical connections and install the nut.
l Install the rubber boot.
2007 Ford Fusion SE
Fig. 555: Locating Pin-Type Retainer And Generator Electrical Connections

135. Install the generator splash shield and the 2 nuts.

2007 Ford Fusion SE
Fig. 556: Locating Generator Splash Shield And Nuts

136. Connect the CKP sensor electrical connector and harness pin-type retainer.
Fig. 557: Locating Crankshaft Position (CKP) Sensor Electrical Connector And Harness Pin-Type
Retainer
137. Install the accessory drive belt idler pulley.

Fig. 558: Locating Accessory Drive Belt Idler Pulley Bolt

NOTE: Clean the coolant pump mating surface with metal surface cleaner.
NOTE: Lubricate the new coolant pump O-ring with clean engine coolant.
138. Install the new O-ring, coolant pump and the 3 bolts.
2007 Ford Fusion SE
Fig. 559: Locating Coolant Pump Bolts

139. Install the coolant pump pulley and the 3 bolts.

Fig. 560: Locating Coolant Pump Pulley Bolts

140. Install the A/C compressor and the 3 bolts.

Fig. 561: Locating A/C Compressor Bolts

141. Install the A/C manifold and the bolt.

2007 Ford Fusion SE
Fig. 562: Locating A/C Manifold And Bolt

142. Connect the A/C compressor electrical connector.
Fig. 563: Locating A/C Compressor Electrical Connector

143. Position the coolant hose on the engine and connect the coolant hose to the throttle body.
Fig. 564: Locating Coolant Hose

144. Connect the lower radiator and heater hoses to the thermostat housing.
2007 Ford Fusion SE
Fig. 565: Locating Lower Radiator And Heater Hoses From Thermostat Housing
145. Connect the KS electrical connector and the 2 harness pin-type retainers.
Fig. 566: Locating Knock Sensor (KS) Electrical Connector And Harness Pin-Type Retainers
146. Install the power steering pump and the lower bolt.
l Finger tighten the bolt.
Fig. 567: Locating Power Steering Pump And Lower Bolt

147. Install the 2 upper power steering pump bolts.

l Tighten all 3 power steering bolts to 25 Nm (18 lb-ft).
2007 Ford Fusion SE
Fig. 568: Locating Upper Power Steering Pump Bolts

148. Connect the power steering pressure (PSP) switch electrical connector.
Fig. 569: Locating Power Steering Pressure (PSP) Switch Electrical Connector
149. Install the accessory drive belt tensioner and the 2 bolts.
Fig. 570: Locating Accessory Drive Belt Tensioner Bolts

150. Position the accessory drive belt onto the tensioner and all of the accessory drive pulleys except the
coolant pump pulley.
151. Using the hex feature, rotate the accessory drive belt tensioner clockwise and install the accessory drive
2007 Ford Fusion SE
belt onto the coolant pump pulley.
Fig. 571: Rotating Accessory Drive Belt Tensioner Clockwise

152. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the engine stand.
Vehicles with automatic transaxle
153. Install the flexplate and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:

Vehicles with manual transaxle
154. Install the flywheel and the 6 bolts. Tighten the 6 bolts in the sequence shown in 3 stages:
2007 Ford Fusion SE

155. Install the starter motor isolator.
Fig. 574: Locating Starter Motor Isolator

156. Lubricate the transaxle input shaft pilot bearing with front axle grease.
Fig. 575: Lubricating Transaxle Input Shaft Pilot Bearing With Front Axle Grease
157. Using the special tool, position the clutch disc on the flywheel.
2007 Ford Fusion SE
Fig. 576: Positioning Clutch Disc On Flywheel Using Special Tool (308-006)
NOTE: If reusing the clutch pressure plate and flywheel, align the marks made
during removal.
158. Position the clutch pressure plate and install the 6 bolts.
l Tighten to 29 Nm (21 lb-ft) in a star pattern sequence.
INSTALLATION
ENGINE - AUTOMATIC TRANSAXLE
Special Tools
303-D089 (D93P-6001-A3) or
Spreader Bar
equivalent
2007 Ford Fusion SE
303-D095 (D94L-6001-A) or
equivalent
Material
Item Specification
Motor Oil
All vehicles
1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the engine-to-
transaxle bolts.
2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
2007 Ford Fusion SE

4. Connect the transaxle pressure switch electrical connector.
Fig. 578: Locating Transaxle Pressure Switch Electrical Connector

5. Connect the output shaft speed (OSS) sensor electrical connector.
2007 Ford Fusion SE
Fig. 579: Locating Output Shaft Speed (OSS) Sensor Electrical Connector
6. Connect the turbine shaft speed (TSS) sensor electrical connector.
Fig. 580: Locating Turbine Shaft Speed (TSS) Sensor Electrical Connector
7. Connect the transaxle control electrical connectors.
Fig. 581: Locating Transaxle Control Electrical Connectors

8. Connect the transmission range (TR) sensor and primary control solenoid electrical connectors.
2007 Ford Fusion SE
Fig. 582: Locating Transmission Range (TR) Sensor And Primary Control Solenoid Electrical
Connectors
9. Install the engine wiring harness bracket and nut.


10. Install the ground wire and bolt.


11. Install new torque converter nuts.
2007 Ford Fusion SE
Fig. 585: Locating Torque Converter Nut

12. Install the starter and the 2 stud bolts.


13. Connect the starter wires and install the 2 nuts.

l Tighten the large nut to 12 Nm (9 lb-ft).
l Tighten the small nut to 5 Nm (44 lb-in).

2007 Ford Fusion SE
14. Attach the 2 wiring harness retainers to the starter stud bolts.
15. Raise the engine and transaxle into the vehicle.
16. Install the 2 transaxle mount bolts.

17. Install the engine mount bracket, 2 nuts and the bolt.
l Tighten the nuts to 103 Nm (76 lb-ft).
l Tighten the bolt to 115 Nm (85 lb-ft).

18. Install the AIR pump and the 3 bolts.

2007 Ford Fusion SE
Fig. 590: Locating AIR Pump Bolts

19. Connect the AIR pump electrical connector.
Fig. 591: Locating AIR Pump Electrical Connector

All vehicles


2007 Ford Fusion SE

22. Install the RH halfshaft into the transaxle.

23. Install the 2 RH halfshaft carrier bearing bracket bolts.


NOTE: Start one end of the circlip in the groove and work the circlip over the
2007 Ford Fusion SE
halfshaft and into the groove to prevent the circlip from overexpanding.
24. Install a new circlip in the groove on the LH halfshaft.
Fig. 596: Locating Halfshaft Circlip

25. Install LH halfshaft into the transaxle.

26. Connect the lower radiator hose and install the retaining clip.
Fig. 597: Identifying Lower Radiator Hose And Installing Retaining Clip
27. Install the radio frequency interference capacitor and the bolt on the engine mount bracket.
2007 Ford Fusion SE
28. Connect the A/C tube to the condenser and install the nut.

29. Connect the A/C tubes and install the 2 nuts.


30. Install the 2 A/C tube bracket bolts.

2007 Ford Fusion SE

31. Attach the coolant vent hose retaining clip to the A/C tube.

32. Install the radio frequency interference capacitor, ground wire and the bolt.
33. Connect the power steering cooler tube.

2007 Ford Fusion SE
34. Connect the transaxle cooler tubes.
Fig. 605: Locating Transaxle Cooler Tubes

35. Connect the transaxle control cable to the bracket.

l Attach the control cable to the control lever.
Fig. 606: Locating Transaxle Control Cable From Control Lever

36. Connect the heater hose inline connector.

37. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the
2007 Ford Fusion SE
heater hose.
38. Connect the upper radiator and heater hoses to the coolant bypass.

39. Attach the evaporative emissions (EVAP) tube bundle retaining clip to the bracket.
40. Connect the EVAP tube to the intake manifold.
2007 Ford Fusion SE
41. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
42. Connect the crankcase vent tube to the valve cover.

43. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM -
44. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
2007 Ford Fusion SE
45. Install the ground wire and the bolt.


46. Connect the 2 engine wiring harness electrical connectors.

47. Connect the wire and install the nut on the battery cable.
2007 Ford Fusion SE

49. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE
50. Install the generator air inlet duct, bolt and the 2 nuts.
51. Place the subframe assembly on the special tool and raise the subframe into the installed position.
2007 Ford Fusion SE

52. Install the front subframe nuts.


53. Position the subframe brackets and install the bolts finger-tight.
Fig. 621: Locating Subframe Brackets Bolts

2007 Ford Fusion SE
54. Install the subframe nuts.


55. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).

56. Install the through bolts into the lower control arms.
2007 Ford Fusion SE

57. Install the lower ball joint nuts.


58. Install the sway bar links and nuts to the struts.
2007 Ford Fusion SE

60. Install tie-rod ends and nuts.

l Install the cotter pin.

61. Install the LH splash shield and the 6 pin-type retainers (4 shown).
2007 Ford Fusion SE

62. Position the LH fender splash shield and install the 4 screws.

63. Install the RH splash shield and the 6 pin-type retainers (4 shown).

64. Position the RH fender splash shield and install the 4 screws.
2007 Ford Fusion SE

65. Install the engine roll restrictor bolt.


66. Route the power steering pressure (PSP) tube up into the engine compartment.
Fig. 634: Locating Power Steering Pressure (PSP) Tube

67. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
l From under the vehicle, verify that the seal is properly installed on the steering gear and the
retaining clips are fully engaged into the dash.
2007 Ford Fusion SE

68. Install the oil filter element. For additional information, refer to Engine Lubrication Components -
69. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .

71. Connect the PSP tube to the power steering pump and install the bolt.

2007 Ford Fusion SE
NOTE: Align the index marks made during removal.
72. Install the steering intermediate shaft onto the steering gear and install the bolt.
Fig. 638: Locating Steering Intermediate Shaft Bolt

73. Install the steering joint cover and the 2 nuts.


75. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
76. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
77. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL
INFORMATION .
78. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL
ENGINE - MANUAL TRANSAXLE
Special Tools
2007 Ford Fusion SE
303-D089 (D93P-6001-A3) or
Spreader Bar
equivalent
303-D095 (D94L-6001-A) or
equivalent
Material
Item Specification
Motor Oil
1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the transaxle-
to-engine bolts.
2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
2007 Ford Fusion SE

4. Connect the vehicle speed sensor (VSS) electrical connector.
Fig. 641: Locating Vehicle Speed Sensor (VSS) Electrical Connector

5. Connect the backup lamp electrical connector.
2007 Ford Fusion SE
Fig. 642: Locating Backup Lamp Electrical Connector

6. Install the engine wiring harness bracket and nut.


7. Install the ground wire and bolt.


8. Install the starter and the 2 stud bolts.

2007 Ford Fusion SE

9. Connect the starter wires and install the 2 nuts.

l Tighten the large nut to 12 Nm (9 lb-ft).
l Tighten the small nut to 5 Nm (44 lb-in).

10. Attach the 2 wiring harness retainers to the starter stud bolts.
11. Raise the engine and transaxle into the vehicle.
12. Install the 2 transaxle mount bolts.

2007 Ford Fusion SE
13. Install the engine mount bracket, 2 nuts and the bolt.
l Tighten the nuts to 103 Nm (76 lb-ft).
l Tighten the bolt to 115 Nm (85 lb-ft).




2007 Ford Fusion SE

16. Install the RH halfshaft into the transaxle.

17. Install the 2 RH halfshaft carrier bearing bracket bolts.


NOTE: Start one end of the circlip in the groove and work the circlip over the
halfshaft and into the groove to prevent the circlip from overexpanding.
18. Install a new circlip in the groove on the LH halfshaft.
2007 Ford Fusion SE
Fig. 653: Locating Halfshaft Circlip

19. Install LH halfshaft into the transaxle.

20. Connect the lower radiator hose and install the retaining clip.
Fig. 654: Identifying Lower Radiator Hose And Installing Retaining Clip
21. Install the radio frequency interference capacitor and the bolt on the engine mount bracket.

22. Connect the A/C tube to the condenser and install the nut.
2007 Ford Fusion SE

23. Connect the A/C tubes and install the 2 nuts.


24. Install the 2 A/C tube bracket bolts.


25. Attach the coolant vent hose retaining clip to the A/C tube.
2007 Ford Fusion SE

26. Install the radio frequency interference capacitor, ground wire and the bolt.

28. Attach the transaxle control cables to the bracket.

l Connect the control cables to the control levers.
2007 Ford Fusion SE
Fig. 662: Locating Control Cables

29. Install the clutch slave cylinder and the 2 bolts.

Fig. 663: Locating Clutch Slave Cylinder Bolts

30. Install the 2 clutch tube bracket bolts.

Fig. 664: Locating Clutch Tube Bracket Bolts

31. Connect the heater hose inline connector.
2007 Ford Fusion SE

32. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the
heater hose.
33. Connect the upper radiator and heater hoses to the coolant bypass.

34. Attach the evaporative emissions (EVAP) tube bundle retaining clip to the bracket.
2007 Ford Fusion SE
35. Connect the EVAP tube to the intake manifold.
36. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
37. Connect the crankcase vent tube to the valve cover.
2007 Ford Fusion SE

38. Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM -
39. Connect the powertrain control module (PCM) electrical connector and the pin-type retainer.
40. Install the ground wire and the bolt.


41. Connect the 2 engine wiring harness electrical connectors.
2007 Ford Fusion SE

42. Connect the wire and install the nut on the battery cable.

44. Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE
45. Install the generator air inlet duct, bolt and the 2 nuts.
2007 Ford Fusion SE
46. Place the subframe assembly on the special tool and raise the subframe into the installed position.

47. Install the front subframe nuts.

2007 Ford Fusion SE

48. Position the subframe brackets and install the bolts finger-tight.
Fig. 679: Locating Subframe Brackets Bolts

49. Install the subframe nuts.


2007 Ford Fusion SE
50. Tighten the subframe bracket-to-body bolts to 103 Nm (76 lb-ft).

51. Install the through bolts into the lower control arms.

52. Install the lower ball joint nuts.

2007 Ford Fusion SE

53. Install the sway bar links and nuts to the struts.


2007 Ford Fusion SE
55. Install tie-rod ends and nuts.

l Install the cotter pin.

56. Install the LH splash shield and the 6 pin-type retainers (4 shown).

57. Position the LH fender splash shield and install the 4 screws.

2007 Ford Fusion SE
58. Install the RH splash shield and the 6 pin-type retainers (4 shown).

59. Position the RH fender splash shield and install the 4 screws.

60. Install the engine roll restrictor bolt.


61. Route the power steering pressure (PSP) tube up into the engine compartment.
2007 Ford Fusion SE
Fig. 692: Locating Power Steering Pressure (PSP) Tube

62. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
l From under the vehicle, verify that the seal is properly installed on the steering gear and the
retaining clips are fully engaged into the dash.

63. Install the oil filter element. For additional information, refer to Engine Lubrication Components -
64. Install the exhaust flexible pipe. For additional information, refer to EXHAUST SYSTEM .

2007 Ford Fusion SE
66. Connect the PSP tube to the power steering pump and install the bolt.

NOTE: Align the index marks made during removal.
67. Install the steering intermediate shaft onto the steering gear and install the bolt.
Fig. 696: Locating Steering Intermediate Shaft Bolt

68. Install the steering joint cover and the 2 nuts.
2007 Ford Fusion SE

70. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND
CABLES .
71. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
72. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL
INFORMATION .
73. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL

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2007 Ford Fusion SE

2007 ENGINE Engine - 2.3L - Fusion, Milan & MKZ

Engine - 2.3L - Fusion, Milan & MKZ

martes, 9 de junio de 2020 09:00:13

Main bearing journal diameter (2.046-2.047 in)

a No. 3 Journal - Supported by No. 1 and No. 5 journals.

A/C tube connection nut 8 - 71

Engine-to-bellhousing stud bolt 48 35 -

Starter motor solenoid nut 5 - 44

a Refer to procedure for specification.

DESCRIPTION AND OPERATION

VALVE CLEARANCE CHECK

Fig. 1: Measuring Each Valve's Clearance Using A Feeler Gauge

NOTE: A midrange clearance is the most desirable:

l Intake: 0.22-0.28 mm (0.008-0.011 in)

Select the tappets and mark the installation location.

BALANCE SHAFT BACKLASH

Timing Peg, Crankshaft TDC

Fig. 2: Installing Crankshaft TDC Timing Peg

Fig. 3: Locating Balancer Unit And Shafts Mark

Remove the 4 bolts and the balancer unit.

Fig. 4: Locating Balancer Unit Bolts

Fig. 5: Locating Balancer Unit And Shafts Reference Mark

7. Install the balancer unit bolts.

l Stage 1: Tighten to 25 Nm (18 lb-ft).

l Stage 2: Tighten to 50 Nm (37 lb-ft).

Fig. 6: Identifying Balancer Unit Bolts Tightening Sequence

8. Remove the Crankshaft TDC Timing Peg.

Fig. 7: Installing Crankshaft TDC Timing Peg

Fig. 8: Installing Crankshaft TDC Timing Peg

Fig. 9: Measuring Gear Backlash

l Remove the balancer unit from the cylinder block.

Fig. 10: Adjustment Shim Selection Chart

Fig. 11: Installing Crankshaft TDC Timing Peg

Fig. 12: Locating Balancer Unit And Shafts Reference Mark

14. Install the balancer unit bolts.

l Stage 1: Tighten to 25 Nm (18 lb-ft).

l Stage 2: Tighten to 50 Nm (37 lb-ft).

Fig. 13: Identifying Balancer Unit Bolts Tightening Sequence

Fig. 14: Measuring Gear Backlash

Fig. 15: Exploded View Of Intake Manifold With Torque Specifications (1 Of 4)

Item Part Number Description

Fig. 16: Exploded View Of Intake Manifold (2 Of 4)

Item Part Number Description

11 14A464 electrical connector (part of 12B637)

Fig. 17: Exploded View Of Intake Manifold With Torque Specification (3 Of 4)

Item Part Number Description

19 9U550 Fuel rail insulator

Fig. 18: Exploded View Of Intake Manifold With Torque Specifications (4 Of 4)

Item Part Number Description

REMOVAL AND INSTALLATION

Fig. 21: Locating Fuel Rail Insulator Retainers

9. Detach the electrical connector pin-type retainer.

Fig. 22: Locating Electrical Connector Pin-Type Retainer

10. If equipped, remove the 7 screws and the underbody cover.

Fig. 23: Locating Underbody Cover Screws

Vehicles equipped with manual transaxle

Vehicles with secondary air injection (AIR)

12. Disconnect the AIR pump electrical connector.

14. Disconnect the vacuum hose from the intake manifold.