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Engine - 3.0L (4V): Other Ford Fusion I facelift

Mechanical 31 illustrations ~715 words

Material

ItemSpecificationFill Capacity
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft Premium Gold Engine Coolant with Bittering Agent (bittered in US only) VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)WSS-M97B51-A1
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A5.7L (6.0 qt) includes filter change
Silicone Brake Caliper Grease and Dielectric Compound XG-3-AESE-M1C171-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4
Silicone Gasket Remover ZC-30
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

Exhaust Emission Control System

Operation and required maintenance of the exhaust emission control devices used on this engine are covered in the Introduction - Gasoline Engines article.

Induction System

The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel injectors

  1. are mounted between the fuel rail and the intake manifold.
  2. meter fuel into the air intake stream in accordance with engine demand.
  3. are positioned so that their tips direct fuel just ahead of the engine intake valves.

Valve Train

The camshafts are mounted in the cylinder heads and act against a roller follower to open and close the valves. A hydraulic lash adjuster is located on one side of the roller follower and the valve tip on the opposite end. The camshafts are driven off the front of each cylinder head by 2 chains (one each side). Both of the chains are driven by sprockets that are located on the crankshaft, just in front of the oil pump.

Positive Crankcase Ventilation System

All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.

Oil Pump

The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire operating range.

The heart of the system is a positive displacement internal gear oil pump.

Generically this design is known as a gerotor pump, which operates as follows

  1. The oil pump is mounted on the front face of the cylinder block.
  2. The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
  3. System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
  4. Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at hot idle and maximum speed.
  5. The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
  6. The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.

Cooling System

The engine cooling system includes the following components

  1. Radiator
  2. Electric cooling fan motor
  3. Degas bottle (aids in maintaining the correct volume of engine coolant)
  4. Coolant thermostat
  5. Coolant hoses

Scheme 123

Scheme 123: Engine Cylinder Identification
Scheme 123: Engine Cylinder Identification

For basic engine mechanical concerns, refer to ENGINE SYSTEM - GENERAL INFORMATION article. For driveability concerns, refer to the Introduction - Gasoline Engines article.

Scheme 124

Scheme 124: Upper Intake Manifold
Scheme 124: Upper Intake Manifold
ItemPart NumberDescription
1Wiring harness retainer (part of 12B637)
214A464Manifold Absolute Pressure (MAP) sensor electrical connector (part of 12B637)
3PCV hose clamp (part of 6K817)
46K817PCV hose
5392984Brake booster vacuum hose clamp
62C053Brake booster vacuum hose
72C053Throttle Body (TB) electrical connector (part of 12B637)
8EGR tube nut (part of 9D477)
914A464EGR valve electrical connector (part of 12B637)
10Vacuum tube
11Vacuum tube retainer bolt
12Wiring harness retainer (part of 12B637)

Scheme 125

Scheme 125
Scheme 125
ItemPart NumberDescription
13W709168TB bolt (4 required)
149F991TB
159E936TB gasket
169Y450Upper intake manifold bolt (8 required)
179424Upper intake manifold
18Clamp (part of 9D661)
199D661Evaporative Emission (EVAP) tube
209H486Upper intake manifold gasket (6 required)

Valve Cover - LH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

Material

Scheme 126

Scheme 126
Scheme 126
ItemPart NumberDescription
1Upper intake manifold wiring harness retainer (part of 12B637)
214A464Variable Camshaft Timing (VCT) solenoid electrical connector (part of 12B637)
3Power steering hose retainer clip
4Wiring harness retainers (2 required) (part of 12B637)
513A506Wiring harness retainer (2 required) (part of 12B637)
614A464LH Heated Oxygen Sensor (HO2S) electrical connector (part of 12B637)
7Wiring harness retainer (3 required) (part of 12B637)
86754Oil level indicator tube
9W701822Oil level indicator tube stud bolt

Scheme 127

Scheme 127
Scheme 127
ItemPart NumberDescription
106758Crankcase ventilation tube
116C519Valve cover stud bolt (10 required)
126A505Valve cover
136C519Valve cover bolt (4 required)
146A559Valve cover gasket
156C527Spark plug cavity gasket (3 required)

Valve Cover - RH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

Material

Scheme 128

Scheme 128
Scheme 128
ItemPart NumberDescription
1W503924Windshield washer bottle and A/C tube retaining clamp bolt
2W503924A/C tube retaining clamp bolt
3W505422A/C tube retaining clamp bolt

Scheme 129

Scheme 129
Scheme 129
ItemPart NumberDescription
4W506413Power Steering Pressure (PSP) tube bracket-to-reservoir bolt
5Wiring harness retainer (part of 12B637)
6W506413PSP tube bracket-to-cylinder head bolt
73A719PSP tube
8Wiring harness retainer (2 required) (part of 12B637)
93493Power steering hose
10Power steering hose clamp (part of 3493)
113R700Power steering reservoir
12W520111Power steering reservoir nut (3 required)
13Power steering hose clamp
143681Power steering hose
15Variable Camshaft Timing (VCT) solenoid electrical connector (part of 12B637)
16Wiring harness retainer (part of 12B637)
17W520411Radio frequency interference capacitor nut
1818801Radio frequency interference capacitor

Scheme 130

Scheme 130
Scheme 130
ItemPart NumberDescription
19506413PSP tube-to-power steering pump banjo bolt
20PSP tube seals
213A719PSP tube

Scheme 131

Scheme 131
Scheme 131
ItemPart NumberDescription
226C519Valve cover stud bolt (4 required)
236K817PCV hose
2414A464PCV valve electrical connector (part of 12B637)
256C519Valve cover bolt (10 required)
266582Valve cover
276584Valve cover gasket
286C527Spark plug cavity gasket (3 required)

Crankshaft Pulley

Special Tools Illustration Tool Name Tool Number 3-Jaw Puller 303-D121 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Strap Wrench 303-D055 (D85L-6000-A)

Scheme 132

Scheme 132: Crankshaft Pulley
Scheme 132: Crankshaft Pulley

Scheme 133

Scheme 133
Scheme 133

Scheme 134

Scheme 134
Scheme 134

Scheme 135

Scheme 135
Scheme 135
ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

Material

Crankshaft Front Seal

Special Tools Illustration Tool Name Tool Number Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Remover, Oil Seal 303-409 (T92C-6700CH)

Scheme 136

Scheme 136
Scheme 136
ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Crankshaft Rear Seal

Special Tools Illustration Tool Name Tool Number Installer Bolts, Crankshaft Rear Main Oil Seal 303-384 (T91P-6701-A) Installer, Crankshaft Rear Main Oil Seal 303-178 (T82L-6701-A) Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH) Slide Hammer 307-005 (T59L-100-B)

Scheme 137

Scheme 137: Crankshaft Rear Seal
Scheme 137: Crankshaft Rear Seal

Scheme 138

Scheme 138
Scheme 138

Scheme 139

Scheme 139
Scheme 139
ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Engine Front Cover

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

Material

Scheme 140

Scheme 140
Scheme 140
ItemPart NumberDescription
1W701234Power steering pump bolt
2W701526Power steering pump bolt (2 required)
3Wiring harness retainer (part of 12B637)
414A464Crankshaft Position (CKP) sensor electrical connector (part of 12B637)
514A464Generator electrical connector (part of 12B637)
6W704747Generator bolt
710300Generator
8Wiring harness retainer (part of 12B637)
914A464A/C compressor electrical connector (part of 12B637)
10W707669Generator stud bolt
11Wiring harness retainer (part of 12B637)
1214A464Engine Oil Pressure (EOP) switch electrical connector (part of 12B637)

Scheme 141

Scheme 141
Scheme 141
ItemPart NumberDescription
13W701525Engine front cover bolt (8 required)
1414A464LH Camshaft Position (CMP) sensor electrical connector (part of 12B637)
15W708222Engine front cover bolt (3 required)
16W708221Engine front cover bolt (3 required)
17W710030Engine front cover stud bolt (2 required)
1814A464RH CMP sensor electrical connector (part of 12B637)
196019Engine front cover
20Engine front cover gaskets (3 required)
21W709678Oil pan-to-front cover bolt (2 required)

Camshaft Roller Follower

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-473 (T94P-6565-BH)

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Hydraulic Lash Adjuster

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Valve Spring, Retainer, and Seal

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-473 (T94P-6565-BH) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 142

Scheme 142: Valve Spring, Retainer, and Seal
Scheme 142: Valve Spring, Retainer, and Seal
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Cylinder Head - RH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30

Material

Scheme 143

Scheme 143
Scheme 143
ItemPart NumberDescription
16065Cylinder head bolt (8 required)
26529Camshaft roller follower (12 required)
36049Cylinder head
4506413Power Steering Pressure (PSP) tube bracket-to-cylinder head bolt
53A719PSP tube bracket
66051Cylinder head gasket
7Wiring harness retainer bolt

Cylinder Head - LH

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket Remover ZC-30

Material

Scheme 144

Scheme 144
Scheme 144
ItemPart NumberDescription
16065Cylinder head bolt (8 required)
26529Camshaft roller follower (12 required)
36050Cylinder head
48501Coolant pump
5701544Coolant pump bolt
66083Cylinder head gasket

Oil Pan

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A
Silicone Gasket and Sealant TA-30WSE-M4G323-A4

Material

Oil Pump Screen and Pickup Tube

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Oil Level Indicator and Tube

ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Scheme 145

Scheme 145
Scheme 145
ItemPart NumberDescription
1Block heater wiring harness (if equipped)
2110282Oil level indicator O-ring seal
36754Oil level indicator tube
4W701822Oil level indicator tube stud bolt

Engine Oil Pressure (EOP) Switch

ItemSpecification
Thread Sealant with PTFE TA-24WSK-M2G350-A2

Material

Scheme 146

Scheme 146
Scheme 146
ItemPart NumberDescription
16714Engine oil filter
214A464Engine Oil Pressure (EOP) switch electrical connector (part of 12B637)
39278EOP

Exhaust Manifold - RH, All Wheel Drive (AWD)

ItemSpecification
Motorcraft Metal Surface Prep ZC-31-A

Material

Scheme 147

Scheme 147
Scheme 147
ItemPart NumberDescription
15K291RH catalytic converter heat shield
2W701706RH exhaust manifold nut (6 required)
39430RH exhaust manifold
4W701732RH exhaust manifold stud (6 required)
59448RH exhaust manifold gasket

Engine Mount

Special Tools Illustration Tool Name Tool Number Lifting Brackets, Engine 303-050 (T70P-6000) Support Bar, Engine 303-F072 Universal Adapter Brackets 014-0001

Scheme 148

Scheme 148: Engine Mount
Scheme 148: Engine Mount

Scheme 149

Scheme 149
Scheme 149

Scheme 150

Scheme 150
Scheme 150
ItemPart NumberDescription
1W711879Damper bolt
27458Damper
3W711684Engine mount bracket bolt
4W705936Ground wire bolt
519A095Ground wire
6W520213Engine support insulator bracket nut (3 required)
76A094Engine mount bracket
8W711578Engine mount nut
9W706496Engine mount bolt (2 required)
106F012Engine mount

Cylinder Head

Special Tools Illustration Tool Name Tool Number Compressor, Valve Spring 303-300 (T87C-6565-A) Compressor, Valve Spring 303-350 (T89P-6565-A) Installer, Valve Stem Oil Seal 303-470 (T94P-6510-CH)

Scheme 151

Scheme 151: Cylinder Head
Scheme 151: Cylinder Head

Scheme 152

Scheme 152
Scheme 152
ItemSpecification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalentWSS-M2C930-A

Material

Scheme 153

Scheme 153
Scheme 153
ItemPart NumberDescription
16C501Hydraulic lash adjuster (12 required)
26518Valve spring retainer key (24 required)
36514Valve spring retainer (12 required)
46513Valve spring (12 required)
56A517Valve stem seal (12 required)
66507Exhaust valve (6 required)
76505Intake valve (6 required)

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