Engine — Automatic Transaxle Printable View (1992 KB) WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury. All vehicles 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100 - 02 . 2. Release the fuel system pressure. For additional information, refer to Section 310 - 00 . 3. Disconnect the battery ground cable. For additional information, refer to Section 414 - 01 . 4. Recover the A/C system. For additional information, refer to Section 412 - 00 . 5. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent). Using a suitable holding device, hold the steering wheel in the straight-ahead position. 6. Remove the 2 nuts and the steering joint cover. SECTION 303-01A: Engine — 2.3L 2006 Fusion/Milan/Zephyr Workshop Manual REMOVAL Procedure revision date: 10/16/2007 Special Tool(s) Heavy Duty Floor Crane 014-00071 or equivalent Powertrain Lift 014-00765 or equivalent Remover, Tie-Rod End 211-105 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent Universal Adapter Brackets 014-0001 or equivalent Page 1 of 13 2006 Fusion/Milan/Zephyr Workshop Manual 7/27/2009 http://www.fordtechservice.dealerconnection.com/pubs/content/~WS6S/~MUS~LEN/20/S...
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~W€¦ · 28/07/2009 · 7. NOTICE: 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
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WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Release the fuel system pressure. For additional information, refer to Section 310-00.
3. Disconnect the battery ground cable. For additional information, refer to Section 414-01.
4. Recover the A/C system. For additional information, refer to Section 412-00.
5. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Remove the 2 nuts and the steering joint cover.
7. NOTICE: 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 Section 501-20B.
NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.
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. Route the PSP tube out the bottom of the engine compartment.
9. Drain the cooling system. For additional information, refer to Section 303-03.
10. If equipped, remove the 7 screws and the underbody cover.
11. Remove the exhaust flexible pipe. For additional information, refer to Section 309-00.
12. Remove the LH halfshaft and the intermediate shaft. For additional information, refer to Section 205-04.
13. NOTICE: The steering gear-to-dash seal must be removed or it will be damaged when lowering the subframe.
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.
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28. Remove the engine oil pan drain plug and drain the engine oil. Install the drain plug and tighten to 28 Nm (21 lb-ft).
29. Remove the oil filter element. For additional information, refer to Engine Lubrication Components — Exploded View and Oil Filter Element in this section.
30. Remove the bolt, 2 nuts and the generator air inlet duct.
31. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to Section 303-12A.
32. Remove the battery tray. For additional information, refer to Section 414-01.
33. Remove the nut and disconnect the wire from the battery cable.
Page 5 of 132006 Fusion/Milan/Zephyr Workshop Manual
58. Remove the 3 bolts and position the AIR pump aside.
All vehicles
59. NOTE: Position a suitable block of wood under the transaxle.
Install the Powertrain Lift and Universal Adapter Brackets onto the engine. Raise the engine and transaxle 25.4 mm (1 in) to neutralize the engine and transaxle mounts.
60. Remove the 2 transaxle mount bolts.
61. Remove the bolt, 2 nuts and the engine mount bracket.
Page 10 of 132006 Fusion/Milan/Zephyr Workshop Manual