FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.
Home >> Ford >> 2010 >> Fusion AWD V6-3.5L >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Engine - Assembly >> Part 4

Part 4




Engine

All vehicles

116. Install 6 new LH exhaust manifold studs.
- Tighten to 12 Nm (106 lb-in).





117. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust manifold to develop an exhaust leak.

Using a new gasket, install the LH exhaust manifold and 6 new nuts. Tighten in 2 stages in the sequence shown:

- Stage 1: Tighten to 20 Nm (177 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).





118. Install the LH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





119. Using a new gasket, install the LH catalytic converter and the 4 new nuts (3 shown).
- Tighten to 40 Nm (30 lb-ft).





120. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).





121. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).





122. Install the Power Steering Pressure (PSP) tube bracket and bolt to the RH cylinder head.
- Tighten to 10 Nm (89 lb-in).





123. Install the PSP hose bracket nut.
- Tighten to 9 Nm (80 lb-in).





124. Attach the PSP hose retainer to the engine lifting eye.





125. Install the generator, the nut and the bolt.
- Tighten to 48 Nm (35 lb-ft).






126. Using new O-ring seals, install the A/C manifold and the bolt.
- Tighten to 25 Nm (18 lb-ft).





127. Position the wiring harness onto the engine.

128. Connect the EOP switch electrical connector and the wiring harness pin-type retainer.





129. Attach the wiring harness retainer to the generator.





130. Connect the generator electrical connector.





131. Connect the generator B+ cable and install the nut.
- Tighten to 12 Nm (106 lb-in).





132. Connect the A/C compressor electrical connector.





133. Connect the CKP sensor electrical connector.





134. Install the wiring harness grommet.





135. Install the wiring harness retainer stud bolt.
- Tighten to 10 Nm (89 lb-in).





136. Install the heat shield, the nut and the bolt.
- Tighten to 10 Nm (89 lb-in).





137. Install the wiring harness retainer bolt on the rear of the LH cylinder head.
- Tighten to 10 Nm (89 lb-in).





138. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

139. Connect the LH camshaft VCT solenoid electrical connector.





140. Connect the 3 LH coil-on-plug electrical connectors.





141. Connect the LH HO2S electrical connector.





142. Connect the LH Catalyst Monitor Sensor (CMS) electrical connector.





143. Connect the LH CMP sensor electrical connector.





144. Connect the CHT sensor electrical connector.





145. Connect the 6 fuel injector electrical connectors (3 shown).





146. Connect the KS electrical connector.





147. Connect the RH CMP sensor electrical connector.





148. Connect the coolant bypass hose to the thermostat housing.





149. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

150. Connect the 3 RH coil-on-plug electrical connectors.





151. Connect the RH VCT solenoid electrical connector.





FWD vehicles

152. Connect the RH CMS electrical connector.





All vehicles

153. Connect the PSP switch electrical connector.





154. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Using new gaskets, install the upper intake manifold and the 6 bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





155. Install the upper intake manifold support bracket and the 2 bolts (one shown).
- Tighten to 10 Nm (89 lb-in).





156. Install the RH exhaust manifold heat shield and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





157. Connect the RH HO2S electrical connector.





158. Attach the wiring harness retainers to the upper intake manifold.





159. Connect the Throttle Body (TB) electrical connector.





160. Connect the PCV hose to the PCV valve.





161. If equipped, position the block heater wiring harness onto the engine.
- Attach the block heater wiring harness retainer to the power steering reservoir hose and the PSP hose.





162. If equipped, connect the block heater electrical connector and install the heat shield.





163. If equipped, attach the block heater wiring harness retainer to the upper intake manifold.





164. Install the Engine Lift Eye on the LH cylinder head.





165. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.





166. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.

Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.





167. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.





168. Install the crankshaft sensor ring.





169. Install the flexplate and the 8 bolts.
- Tighten to 80 Nm (59 lb-ft).





pro multis Credits:Operation CHARM About Operation CHARM