Thursday, March 15, 2012

Ford Fusion and Mercury Milan Engine replacing procedure?

The details to replace engine on ford and mercury car models are as follows:----

WITH AUTOMATIC TRANSAXLE:--


Removal & Installation



2.3L Engine
With Automatic Transaxle
Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009
  1. Raise and safely support the vehicle.
  2. Release the fuel system pressure, as outlined in the Fuel Section.
  3. Disconnect the negative battery cable.
  4. Recover the air conditioning system.
  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.
    WARNING
    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.


    NOTE
    Matchmark the installed position of the steering column shaft position to the steering gear for reference during installation.
  7. Remove the bolt and disconnect the steering column shaft from the steering gear.
  8. Remove the bolt and disconnect the power steering pressure (PSP) tube from the power steering pump.
  9. Route the PSP tube out the bottom of the engine compartment.
  10. Drain the cooling system.
  11. If equipped, remove the 7 screws and the underbody cover.
  12. Remove the exhaust flexible pipe.
    WARNING
    The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
  13. Release the 4 clips and slide the steering gear-to-dash seal off of the steering gear and into the passenger compartment.
  14. Remove the engine roll restrictor bolt.
  15. Remove the 4 screws and position the RH fender splash shield aside.
  16. Remove the 6 pin-type retainers (4 shown) and the RH splash shield.
  17. Remove the 4 screws and position the LH fender splash shield aside.
  18. Remove the 6 pin-type retainers (4 shown) and the LH splash shield.
  19. Remove the cotter pins and nuts from the tie-rod ends.
  20. Using a suitable tool, separate the tie-rod ends from the steering knuckles.
  21. Disconnect the power steering cooler tube.
  22. Remove the nuts and separate the sway bar links from the struts.
  23. Remove the lower ball joint nuts.
    WARNING
    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.
  24. Using the special tools, separate the lower ball joints from the lower control arms.

    Click image to see an enlarged view
    Fig. Using the special tools, separate the lower ball joints from the lower control arms
  25. Remove the through bolts from the lower control arms.
  26. Position the special tool under the subframe assembly.

    Click image to see an enlarged view
    Fig. Position the special tool under the subframe assembly
  27. Remove the subframe bracket-to-body bolts.
  28. Remove the subframe nuts and the subframe brackets.
  29. Remove the front subframe nuts.
  30. Lower the subframe assembly from the vehicle.
  31. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 21 ft. lbs. (28 Nm).
  32. Remove the oil filter element.
  33. Remove the bolt, 2 nuts and the generator air inlet duct.
  34. Remove the engine air cleaner and air cleaner outlet pipe.
  35. Remove the battery tray.
  36. Remove the nut and disconnect the wire from the battery cable.
  37. Disconnect the 2 engine wiring harness electrical connectors.
  38. Remove the bolt and the ground wire.
  39. Disconnect the Powertrain Control Module (PCM) electrical connector and the pin-type retainer.
  40. Disconnect the fuel supply tube from the fuel rail.
  41. Disconnect the crankcase vent tube from the valve cover.
  42. Depress the locking ring and disconnect the brake booster vacuum supply tube from the intake manifold.
  43. Disconnect the evaporative emissions (EVAP) tube from the intake manifold.
  44. Detach the retaining clip and position the EVAP tube bundle aside.
  45. Disconnect the upper radiator and heater hoses from the coolant bypass.
  46. If equipped, disconnect the block heater electrical connector and detach the harness retaining clips from the heater hose.
  47. Disconnect the heater hose inline connector.
  48. Disconnect the transaxle control cable from the control lever.
  49. Detach the control cable from the bracket.
  50. Disconnect the transaxle cooler tubes.
  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.
  53. Disconnect the power steering cooler tube.
  54. Remove the 2 A/C tube bracket bolts.
  55. Remove the 2 nuts and disconnect the A/C tubes.
  56. Remove the nut and disconnect the A/C tube from the condenser.
  57. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
  58. Remove the retaining clip and disconnect the lower radiator hose.
  59. Using a suitable tool, separate the LH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
  60. Remove the 2 RH halfshaft carrier bearing bracket bolts.
  61. Separate the RH halfshaft from the transaxle and support the halfshaft with a length of mechanic's wire.
  62. Remove the bellhousing-to-oil pan bolt.
  63. Remove the 2 oil pan-to-bellhousing bolts.
  64. For vehicles with secondary Air Injection (AIR), disconnect the AIR pump electrical connector, then remove the 3 bolts and position the AIR pump aside.
    NOTE
    Position a suitable block of wood under the transaxle.
  65. Install the special tools onto the engine.
  66. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.

    Click image to see an enlarged view
    Fig. Install the special tools onto the engine, then raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts
  67. Remove the 2 transaxle mount bolts.
  68. Remove the bolt, 2 nuts and the engine mount bracket.
  69. Lower the engine and transaxle from the vehicle.
  70. Remove the 2 nuts and disconnect the starter wires.
  71. Detach the 2 wiring harness retainers from the starter stud bolts.
  72. Remove the 2 stud bolts and the starter.
  73. Remove the 4 torque convertor nuts.
  74. Remove the bolt and ground wire.
  75. Remove the nut and position the engine wiring harness bracket aside.
  76. Disconnect the transmission range (TR) sensor and primary control solenoid electrical connectors.
  77. Disconnect the transaxle control electrical connectors.
  78. Disconnect the Turbine Shaft Speed (TSS) sensor electrical connector.
  79. Disconnect the Output Shaft Speed (OSS) sensor electrical connector.
  80. Disconnect the transaxle pressure switch electrical connector.
  81. Install the special tools and remove the engine and transaxle from the powertrain lift table.

    Click image to see an enlarged view
    Fig. Install the special tools and remove the engine and transaxle from the powertrain lift table
  82. Remove the bellhousing-to-engine retainers.
  83. Separate the engine and transaxle.
To install:

CAUTION
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.

  1. Using the engine crane and spreader bar, position the engine and transaxle together. Install the engine-to-transaxle bolts. Tighten to 35 ft. lbs. (48 Nm).
  2. Using the engine crane and spreader bar, position the engine and transaxle onto the lift table.
    NOTE
    Position a suitable block of wood under the transaxle.
  3. Install the special tools onto the engine.
  4. Connect the transaxle pressure switch electrical connector.
  5. Connect the OSS sensor electrical connector.
  6. Connect the TSS sensor electrical connector.
  7. Connect the transaxle control electrical connectors.
  8. Connect the TR sensor and primary control solenoid electrical connectors.
  9. Install the engine wiring harness bracket and nut. Tighten to 15 ft. lbs. (20 Nm).
  10. Install the ground wire and bolt. Tighten to 89 inch lbs. (10 Nm).
  11. Install new torque converter nuts. Tighten to 26 ft. lbs. (35 Nm).
  12. Install the starter and the 2 stud bolts. Tighten to 18 ft. lbs. (25 Nm).
  13. Connect the starter wires and install the 2 nuts:
    1. Tighten the large nut to 9 ft. lbs. (12 Nm).
    2. Tighten the small nut to 44 inch lbs. (5 Nm).
  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. Tighten to 66 ft. lbs. (90 Nm).
  17. Install the engine mount bracket, 2 nuts and the bolt:
    1. Tighten the nuts to 76 ft. lbs. (103 Nm).
    2. Tighten the bolt to 85 ft. lbs. (115 Nm).
  18. For vehicles with secondary AIR:
    1. Install the AIR pump and the 3 bolts and tighten to 22 ft. lbs. (30 Nm).
    2. Connect the AIR pump electrical connector.
  19. Install the 2 oil pan-to-bellhousing bolts. Tighten to 35 ft. lbs. (48 Nm).
  20. Install the bellhousing-to-oil pan bolt. Tighten to 35 ft. lbs. (48 Nm).
  21. Install the RH halfshaft into the transaxle.
  22. Install the 2 RH halfshaft carrier bearing bracket bolts. Tighten to 30 ft. lbs. (40 Nm).
    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 over expanding.
  23. Install a new circlip in the groove on the LH halfshaft.
  24. Install LH halfshaft into the transaxle.
  25. Connect the lower radiator hose and install the retaining clip.
  26. Install the radio frequency interference capacitor and the bolt on the engine mount bracket. Tighten to 89 inch lbs. (10 Nm).
  27. Connect the A/C tube to the condenser and install the nut. Tighten to 71 inch lbs. (8 Nm).
  28. Connect the A/C tubes and install the 2 nuts. Tighten to 71 inch lbs. (8 Nm).
  29. Install the 2 A/C tube bracket bolts. Tighten to 89 inch lbs. (10 Nm).
  30. Attach the coolant vent hose retaining clip to the A/C tube.
  31. Install the radio frequency interference capacitor, ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm).
  32. Connect the power steering cooler tube.
  33. Connect the transaxle cooler tubes.
  34. Connect the transaxle control cable to the bracket. Attach the control cable to the control lever.
  35. Connect the heater hose inline connector.
  36. If equipped, connect the block heater electrical connector and attach the harness retaining clips to the heater hose.
  37. Connect the upper radiator and heater hoses to the coolant bypass.
  38. Attach the EVAP tube bundle retaining clip to the bracket.
  39. Connect the EVAP tube to the intake manifold.
  40. Insert the brake booster vacuum supply tube into the locking ring on the intake manifold.
  41. Connect the crankcase vent tube to the valve cover.
  42. Connect the fuel supply tube to the fuel rail.
  43. Connect the PCM electrical connector and the pin-type retainer.
  44. Install the ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm).
  45. Connect the 2 engine wiring harness electrical connectors.
  46. Connect the wire and install the nut on the battery cable. Tighten to 89 inch lbs. (10 Nm).
  47. Install the battery tray.
  48. Install the engine air cleaner and air cleaner outlet pipe.
  49. Install the generator air inlet duct, bolt and the 2 nuts. Tighten to 53 inch lbs. (6 Nm).
  50. Place the subframe assembly on the special tool and raise the subframe into the installed position.
  51. Install the front subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  52. Position the subframe brackets and install the bolts finger-tight.
  53. Install the subframe nuts. Tighten to 111 ft. lbs. (150 Nm).
  54. Tighten the subframe bracket-to-body bolts to 76 ft. lbs. (103 Nm).
  55. Install the through bolts into the lower control arms. Tighten to 76 ft. lbs. (103 Nm).
  56. Install the lower ball joint nuts. Tighten to 148 ft. lbs. (200 Nm).
  57. Install the sway bar links and nuts to the struts. Tighten to 30 ft. lbs. (40 Nm).
  58. Connect the power steering cooler tube.
  59. Install tie-rod ends and nuts. Tighten to 35 ft. lbs. (48 Nm). Install the cotter pin.
  60. Install the LH splash shield and the 6 pin-type retainers (4 shown).
  61. Position the LH fender splash shield and install the 4 screws.
  62. Install the RH splash shield and the 6 pin-type retainers (4 shown).
  63. Position the RH fender splash shield and install the 4 screws.
  64. Install the engine roll restrictor bolt. Tighten to 66 ft. lbs. (90 Nm).
  65. Route the PSP tube up into the engine compartment.
  66. Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
  67. 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.
  68. Install the oil filter element.
  69. Install the exhaust flexible pipe.
  70. If equipped, install the underbody cover and the 7 screws.
  71. Connect the PSP tube to the power steering pump and install the bolt. Tighten to 26 ft. lbs. (35 Nm).
    NOTE
    Align the matchmarks made during removal.
  72. Install the steering intermediate shaft onto the steering gear and install the bolt. Tighten to 17 ft. lbs. (23 Nm).
  73. Install the steering joint cover and the 2 nuts.
  74. Fill the engine with clean engine oil.
  75. Connect the battery ground cable.
  76. Fill and bleed the cooling system.
  77. Fill the power steering system.
  78. Recharge the air conditioning system.



These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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