Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
2008 Ford Fusion AWD L4-2.3LFACTORY OEM SERVICE PROCEDURE
System Specifications
Cylinder Head Bolts
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
First pass 7 Nm (62 lb-inch)
Second pass 15 Nm (11 lb-ft).
Third pass 45 Nm (33 lb-ft).
Fourth pass Turn 90°
Final pass Turn an additional 90°
Cylinder Block Head Gasket Surface Flatness 0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general) (0.0019 in/7.87 x 7.87)
Intake Manifold Bolts 18 Nm (13 lb-ft).
Camshaft Bearing Cap Bolts
First pass finger tight
Second pass 7 Nm (62 lb-inch).
Final pass 16 Nm (12 lb-ft).
Camshaft Phaser and Sprocket Bolts 72 Nm (53 lb-ft).
Catalytic Converter Manifold Studs 17 Nm (13 lb-ft).
Discard the studs.
Catalytic Converter Manifold Nuts
Discard the nuts.
First pass 55 Nm (41 lb-ft).
Final pass 55 Nm (41 lb-ft).
NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.
First pass 7 Nm (62 lb-inch)
Second pass 15 Nm (11 lb-ft).
Third pass 45 Nm (33 lb-ft).
Fourth pass Turn 90°
Final pass Turn an additional 90°
Cylinder Block Head Gasket Surface Flatness 0.1 mm/general 0.05 mm/200 x 200 (0.004 in/general) (0.0019 in/7.87 x 7.87)
Intake Manifold Bolts 18 Nm (13 lb-ft).
Camshaft Bearing Cap Bolts
First pass finger tight
Second pass 7 Nm (62 lb-inch).
Final pass 16 Nm (12 lb-ft).
Camshaft Phaser and Sprocket Bolts 72 Nm (53 lb-ft).
Catalytic Converter Manifold Studs 17 Nm (13 lb-ft).
Discard the studs.
Catalytic Converter Manifold Nuts
Discard the nuts.
First pass 55 Nm (41 lb-ft).
Final pass 55 Nm (41 lb-ft).
Factory Service Tools
Use the Manual With the Right Hardware
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.