2008 Ford Fusion 2.3L Engine Torque Specs| Ford Specs (2024)

2008 fusion 2.3L Complete Torque Specs List

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Ford fusion 2.3L DOHC Engine Repair Information

Here you can find information regarding the assembly of the Ford 2.3L DOHC engine. In this guide we willstart from the inside of the engine including thecrankshaft, connecting rods, and piston ring installation and then move outwards all the way to the pulley beltsystem. Along the way correct procedures and torque specswill be given to aid in the assembly of the engine. Feel free to start from the beggining and work your wayoutwards or skip ahead to your current position in the engine for what you may need.

Crankshaft Main Caps Installation

The 2.3L engine block main bearing caps should be inspected for any defects or flaws before installation.Be sure to lubricate the bearing surfaces prior to installation. Once prepared you can place the caps onto the crankshaftand begin tightening the bolts down in a multi stage process. The first being 10 ft-lbs starting from the middle and going outwards.The second time around you can go to 32 ft-lbs and then for the third time you do an additional 90 degree turn for each bolt. And finally one last90 degree turn going through each bolt in a cross pattern.Once finished you should be good to continue with the rest of the engine.

fusion 2.3L DOHC Main Cap Torque Specs : 32 ft-lbs + 90° + 90°

Piston and Connecting Rod Installation

To install the pistons and connecting rods you must first install the piston rings into each piston. Be carefulnot to stretch the rings or break them during installation. Make sure to put the correct rings in the correctpositions, this can be determined by looking atthe instructions given with the new rings. Each ring manufacturer is different so be sure to check for yourspecific rings. Once the rings have been installed you can now fit the connecting rod bearings into the end capsand lube them up with oil or lithium grease. The piston can now be lowered into the cylinder, make sure the dotor mark is facing the front of the engine and that you don't scratch the cylinder.Once installed you can match the connecting rod caps with the correct rods and start to torque the connectingrod bolts to 21 ft-lbs and then an additional 90 degree turn for each bolt. After all are done rotate the crankto ensure all pistons move smoothly in and out of their cylinders and nothing binds.

fusion 2.3L DOHC Connecting Rod Torque Specs : 21 ft-lbs + 90°

Oil Pump Installation

When installing the oil pump be sure to use the proper sealant around the pump base if neccessary to ensure that oil pressuredoesn't drop due to leakage. After preparing the contact surfaces carefullyinstall the oil pump onto the engine block by aligning the bolt holes with the pump holes. Onceinstalled tighten the bolts and torque them to 15 ft-lbs. The oil pump pickup tube can be installed onto the pump itself and torqueddown to 8 ft-lbs. After torqueing the bolts besure to prime the pump with the proper engine oil, this ensures that when the engine is initially started thatoil is already present in the pump and that the engine doesn't start without any oil flowinginside of it.

fusion 2.3L DOHC Oil Pump Torque Specs : 15 ft-lbs

fusion 2.3L DOHC Oil Pickup Tube Torque Specs : 8 ft-lbs

Cylinder Head Installation

The first thing you must do when installing cylinder heads is to ensure both the block and head surfaces arecompletely clean from dust, oil, and any debris. The next thing you must to isto set the camshafts to their correct positions to prevent any valves from hitting pistons during installationand torquing of the head bolts. Much the same you have to set the pistons to their correctlocations, typically this means putting the #1 piston to TDC or Top Dead Center. Once everything is ready youcan install the head gasket onto the engine block by aligning the alignment dowels.Something I usually do is spray down the head gasket with some engine copper spray from permatex which you canfind here, this ensures that any gaps that could be present between the 2 surfaces gets filled with thespray. Italso helps to transfer heat between the 2 metals. With the gasket in place you can set the cylinder head ontothe gasket and block, if needed have someone assist with this process as the head can be heavyand you don't want to scratch anything or drop it! Once the head has been placed you will want to startinstalling the head bolts to make sure it doesn't move. Be sure to buy new head bolts as many manufacturersuse TTY or Torque to Yield head bolts meaning they stretch during torqueing and cannot be used twice. Also makesure to lubricate the bolts in clean engine oil before installing them into the head.Once all the head bolts have been installed and finger tightened you can start the torqueing process, almost allhead bolts have a multi-step process for torqueing. The 2.3L DOHC starts off with 33 ft-lbs andthen requires you to back them off a full turn. Then you must again torque them to15 ft-lbs and then 33 ft-lbs and then add 90 degrees by going through each bolt with each step. And then an additional 90 degrees the sameway as the first. After torquing the heads are completely installed and you can now move to intalling the timing.

fusion 2.3L DOHC Cylinder Head Torque Specs : 33 ft-lbs + 90° + 90°

Timing Belt and Tensioner Installation

On the Ford 2.3 Zetec or DOHC engine the timing system is ran by the use of a chain. This timing chain system consists of a sprocket on both of the camshafts, a tensioner, a guide, anda sprocket on the crankshaft. Before installing the chain itself make sure all the components are tight. The camshaft sprockets get tightened to 50 ft-lbs, while the tensioner and idler gets tightened to8 ft-lbs. The camshafts are held down to the cylinder head by camshaft bearing caps which should be tightened to 15 ft-lbs. With the sprockets tight you can move the sprocketsto the correct locations and then install the chain by tensioning the tensioner and placing the chain on the proper timing marks on the sprockets.The correct timing procedure is shown in the picture. Along with the timing system is a crankshaft position sensor which should be tightened to 10 ft-lbs.

fusion Camshaft Sprocket Bolt Torque Spec: 50 ft-lbs

fusion Crankshaft Position Sensor Torque Spec: 15 ft-lbs

fusion Camshaft Bearing Caps Torque Spec : 15 ft-lbs

fusion Timing Chain Tensioner Bolt Torque Spec : 8 ft-lbs

fusion Timing Chain Guide Bolts Torque Spec : 8 ft-lbs

Timing Chain Cover Installation

The timing cover on the 2.3L is used primarily to cover up the timing chain and to keep the engine oil from leaking outside of the engine.It is important to clean both the engine block and the timing cover surfaces before installing the cover. I also advice using new gaskets and somesilicon sealant to aid in the installation as you do not want oil leaking out. When installing the cover double check your timing and then place thecover onto the engine and start installing the bolts. You can start by torqueing them to 15 ft-lbs and then finishing them off at 35 ft-lbs.

fusion Timing Chain Cover Bolts Torque Spec: 35 ft-lbs

Oil Pan Installation

Much like the timing cover on the 2.3L the oil pan plays an important role in keeping the engine oil inside theengine. For this reason I recommend using a new gasket as well as some silicone sealantduring installation. Using the same technique as before with the cover you clean the surfaces of both the oilpan and the engine block and then install the new gasket onto the block and then followit up with some silicone sealant. Be sure to follow your sealants instructions to ensure you get the best sealfrom your application. The oil pan bolts torque to 18 ft-lbs in a crosspattern design.Along with the pan is the oil pan drain plug, this gets removed and reinstalled quite frequently and can betorqued down to 10 ft-lbs.

fusion Oil Pan Torque Specs : 18 ft-lbs

fusion Oil Drain Plug Torque Specs : 10 ft-lbs

Valve Covers Installation

The valve cover installation is rather simple, there are rubber seals for each bolt hole and a silicone gasketthat prevents oil from leaking out of the engine. It is recommended to replace both the sealsand the gaskets although if they are in good condition you can reuse them. If you do choose to reuse them Iwould use some silicone sealant along with the silicon gasket to ensure it does not leak.The valve cover bolts torque down to 106 in-lbs or about 8 ft-lbs in a criss cross order. Be sure not to missany bolts to avoid having oil leak out onto the exhaust pipes and cause a lot of smoking.

fusion Valve Cover Torque Specs : 8 ft-lbs

Intake Manifold and Fuel Rail Installation

When installing the intake manifold you want to make sure you have all the surfaces as well as intake holescleaned out before placing the manifold into position. Once cleaned you can then placethe intake manifold gaskets onto the alignment pins. If you want you can also use a little bit of sealant on thegaskets to help ensure there are no leaks. With the gaskets in place you can now putthe manifold down onto the gaskets and begin to install the bolts. The intake manifold bolts torque to 13 ft-lbsand can be tightened starting from the inside and going outwards. The COPs or the coilsfor the spark plugs get torqued down to 60 in-lbs or about 5 ft-lbs and the spark plugs themselves can betorqued down to 12 ft-lbs, be careful not to overtorque these as they can snap and cause big problems.When installing the fuel rail make sure that all the fuel injectors are in good condition and that all theo-rings are in place andare in good condition. If everything is good you can place the fuel rail into position and push the injectorsinto their holes and start to torque the rail bolts to 90 in-lbs or about 8 ft-lbs.

fusion Intake Manifold Torque Specs : 13 ft-lbs

fusion Ignition Coil Torque Specs : 5 ft-lbs

fusion Spark Plug Torque Specs : 12 ft-lbs

fusion Fuel Rail Torque Specs : 8 ft-lbs

Exhaust Manifold Installation

The exhaust manifold can be installed by cleaning the surface areas on both the head an the manifold itself andthen by using the exhaust manifold gasket and putting it in place. Once the gasket is inlocation you can put the manifold onto the heads and begin to torque the nuts to 40 ft-lbs. I always use somecopper spray from permatex on the exhaust manifold gaskets to ensure I do not end up withany exhaust leaks once done. When you go to install the engine into the vehicle or if it is already in thevehicle the torque specs for the exhaust manifold to the exhaust pipes or catalytic converter is 30 ft-lbs.

fusion Exhaust Manifold Nuts Torque Spec : 40 ft-lbs

fusion Exhaust Pipe Torque Specs : 30 ft-lbs

Water Pump and Thermostat Installation

The water pump on the Ford 2.3L DOHC engine is located between the engine camshaft and crankshaft sprocket. The pump can be installed by usinga new gasket and if desired some silicone sealant to help prevent leaks. Be sure to clean both metal surfaces prior to installing the pump. Onceprepared the pump can be moved into placed and the bolts should be torqued to 8 ft-lbs.The water pump pulley can be torqued to the water pump itself with 18 ft-lbs as well.

fusion Water Pump Torque Specs : 8 ft-lbs

fusion Water Pump Pulley Torque Specs : 18 ft-lbs

Front Dress and Pulley belt Installation

Most of what is left on the engine is just place and tighten objects such as the belt pulleys, belt tensioner,throttle body, oil filter neck, crankshaft pulley, and motor mounts. If the items have a gasket and hold eitheroil or coolant inside the engine then feel free to add some sealant along with the gasket. Always be sure toinspect your gaskets and replace them if there is any deteriation or flaws with them. For thebelt system the crank shaft pulley gets torqued to 85 ft-lbs. The belttensioner can be tightened to 33 ft-lbs and the idler pulley can be torqued down to 18 ft-lbs. When installing be sure theyboth turn smoothly and if they do not then replace them with new ones as the bearings can go bad. The enginemotor mount can be installed onto the engine block if it hasn't been already, the torques forthe mount to the block is 59 ft-lbs and then when installing the mount to the vehicle or frame it can be torqued to35 ft-lbs. Finally the throttle body can be installed on top of the intake manifoldwith a good gasket and some added sealant using 7 ft-lbs in a criss cross pattern. For installing the belt youcan use a tool to move the tensioner into its springed state and install the belt as shown in thepicture.

fusion Crankshaft Pulley Torque Specs : 85 ft-lbs

fusion Idler Pulley Bolt Torque Spec : 18 ft-lbs

fusion Belt Tensioner Torque Specs : 33 ft-lbs

fusion Motor Mount to Engine Torque Specs : 59 ft-lbs

fusion Motor Mount to Frame Torque Specs : 35 ft-lbs