Market Position:
The Mercury Milan was positioned as a mid-size sedan, a competent offering in a highly competitive segment. This workshop manual reflects the factory's commitment to providing comprehensive repair information for this model.
Competitive Analysis:
Competed against vehicles like the Toyota Camry, Honda Accord, Nissan Altima, Chevrolet Malibu, and Ford Fusion (with which it shared a platform). This manual provides the in-depth technical data necessary to maintain and repair it to factory standards.
Key Features:
Factory-level accuracy, comprehensive system coverage, detailed diagnostic procedures, and extensive use of illustrations and diagrams, mirroring the information provided to dealership technicians.
Target Audience:
DIY enthusiasts, independent repair shops, and owners seeking to understand and perform maintenance or repairs on their Mercury Milan.
Coverage Areas:
Comprehensive service and repair for all vehicle systems, including engine mechanical, engine electrical, emission control, fuel system, clutch, manual transaxle, automatic transaxle, driveshaft, axle, suspension, steering, restraint systems, brake system, body (interior and exterior), body electrical, and HVAC.
Page Count:
Estimated 2000+ pages (typical for a comprehensive factory workshop manual).
Manual Type:
Factory Service Workshop Manual
Systems Covered:
Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch System, Manual Transaxle System, Automatic Transaxle System, Driveshaft and Axle, Suspension System, Steering System, Restraint System, Brake System, Body (Interior and Exterior), Body Electrical System, Heating, Ventilation, Air Conditioning (HVAC).
Procedures Included:
Detailed procedures for maintenance, diagnostics, troubleshooting, repair, and overhaul of all covered systems. Includes step-by-step instructions, diagrams, specifications, and torque values. Covers everything from routine oil changes to complete transmission rebuilds.
Technical Depth:
Factory-level technical depth, suitable for professional technicians and advanced DIY enthusiasts. Includes detailed wiring diagrams, component locations, diagnostic trouble codes (DTCs) with interpretations and repair procedures, and specialized tool recommendations.
Searchability:
Searchable text within PDF, facilitated by index.
Compatibility:
Windows 95/98/ME/XP/Vista/7, Linux, macOS
Print Quality:
High-resolution, suitable for printing individual pages or sections.
Binding Type:
Digital Download (N/A for physical binding)
Paper Type:
Digital Download (N/A for physical paper type)
Engine Displacement Liters:
2.3L (standard on base models) and 3.0L (optional on higher trims).
Engine Type:
2.3L: DOHC Inline-4; 3.0L: DOHC V6 (Duratec 30).
Engine Code 2 3L:
Likely GZ (Duratec 23) or similar variant.
Engine Code 3 0L:
Likely AJC (Duratec 30) or similar variant.
Horsepower 2 3L:
Approximately 160-170 hp (varies slightly by year and specific configuration).
Torque 2 3L:
Approximately 150-160 lb-ft (varies slightly by year).
Horsepower 3 0L:
Approximately 200-203 hp.
Torque 3 0L:
Approximately 200-207 lb-ft.
Fuel Delivery:
Electronic Fuel Injection (EFI) with Sequential Port Fuel Injection (SFI).
Emission Standards:
Meets EPA and CARB emission standards relevant to the production years. The manual details specific emission control systems like EGR, catalytic converters, and evaporative emission control.
Coolant Type:
Dex-Cool® or equivalent (typically orange ethylene glycol-based antifreeze).
Oil Type 2 3L:
SAE 5W-20 (API certified, synthetic blend or full synthetic recommended).
Oil Type 3 0L:
SAE 5W-20 (API certified, synthetic blend or full synthetic recommended).
Oil Capacity 2 3L Quarts:
Approx. 5.7 quarts (with filter change).
Oil Capacity 3 0L Quarts:
Approx. 6.0 quarts (with filter change).
Standard Transmission:
5-speed manual transaxle (available on some configurations, typically with the 2.3L engine).
Optional Transmission:
5-speed automatic transaxle (e.g., 5F50N or similar Ford/Getrag unit) available with both engines.
Automatic Transmission Features:
SelectShift™ capability (driver-selectable gear changes), likely with electronic pressure control and adaptive shift logic.
Fluid Specifications Automatic
Automatic Transmission Fluid Type:
MERCON® V or equivalent is typically specified.
Fluid Specifications Manual
Manual Transmission Fluid Type:
Refer to specific manual transaxle identification and specified gear oil type (e.g., synthetic manual transmission fluid).
Wheelbase Inches:
Approx. 107.4 inches.
Length Inches:
Approx. 191.8 inches.
Width Inches:
Approx. 72.1 inches.
Height Inches:
Approx. 57.1 inches.
Curb Weight Lbs 2 3L:
Approx. 3,300 - 3,400 lbs (varies by configuration).
Curb Weight Lbs 3 0L:
Approx. 3,400 - 3,600 lbs (varies by configuration).
Trunk Capacity Cubic Feet:
Approx. 15.8 cubic feet.
NHTSA Front Impact Driver Rating:
Likely 5-star (check specific year testing).
NHTSA Front Impact Passenger Rating:
Likely 5-star (check specific year testing).
IIHS Front Offset Crash Rating:
Good (for models tested).
Active Safety Features:
Anti-lock Braking System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC - likely optional or standard on higher trims).
Passive Safety Features:
Front dual-stage airbags, front side-impact airbags, side-curtain airbags (optional or standard depending on trim), front and rear crumple zones, side-impact door beams.
Restraint System Description:
The manual details the operation, inspection, and replacement of airbags, seat belts (including pretensioners), and related control modules.
Infotainment Features:
Standard AM/FM stereo with CD player, optional Sirius Satellite Radio, MP3 capability, and premium audio systems (e.g., Audiophile). Some models may feature navigation systems.
Driver Assistance Features:
Cruise control, available rear parking sensors.
Connectivity Options:
Optional SiriusXM Satellite Radio. The manual details wiring for audio systems and any available UConnect or SYNC-like systems if applicable, though likely less advanced than later Ford models.
Oil Change Interval Miles:
Typically 5,000 to 7,500 miles or 6 months, whichever comes first, for conventional oil. With full synthetic, this can often be extended. The manual provides the definitive factory recommendation.
Air Filter Replacement Interval Miles:
Recommended every 30,000 miles or as needed based on driving conditions. Manual will specify.
Cabin Air Filter Replacement Interval Miles:
Recommended every 15,000 - 30,000 miles or annually. Manual will specify.
Coolant Flush Interval Miles:
Initial flush at 100,000 miles, then every 50,000 miles thereafter, or as per manual. Manual specifies correct coolant type.
Transmission Fluid Change Interval Miles:
Automatic transmission fluid typically inspected at 30,000 miles; replacement interval varies (e.g., 60,000-100,000 miles depending on use). Manual will detail specific procedures and intervals.
Brake Fluid Type:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification).
Power Steering Fluid Type:
Refer to manual; likely a specific MERCON® type fluid or ATF.
Common Issues:
Potential for occasional transmission issues (e.g., harsh shifting), HVAC blower motor failures, and minor electrical gremlins. The manual provides detailed troubleshooting for these and all other potential problems.
Wheel Bolt Pattern:
5x114.3 mm (5x4.5 inches).
Common Tire Sizes:
Examples: P215/60R16, P225/50R17, P235/45R18 (varies by trim and wheel option).
Brand Heritage:
Mercury was a division of Ford Motor Company, established in 1939 to offer a mid-range product between Ford and Lincoln. The brand aimed for distinctive styling and a touch of luxury compared to mainstream Fords.
Model Evolution:
The Mercury Milan was introduced for the 2006 model year, replacing the Mercury Sable. It was based on the Ford CD3 platform, sharing its underpinnings with the Ford Fusion and Mazda 6. The Milan offered a more upscale interpretation of the Fusion's design and features.
Production Location:
Built at Ford's Hermosillo Stamping and Assembly Plant in Hermosillo, Sonora, Mexico.
Production End Year:
The Mercury brand was discontinued by Ford after the 2011 model year, and the Milan ceased production with the 2011 model year, though the manual covers up to 2009.
