🏷️ Basic Information

Make:

Mercury

Model:

Milan

Year:

2009

Platform:

Ford CD3 Platform

👋 Introduction

Positioning:

A comprehensive factory service repair manual designed for both do-it-yourselfers and experienced mechanics, offering an economical way to maintain vehicle operability.

Competitors:

Offers a distinct advantage over expensive paper-based manuals by providing instant digital access, eliminating shipping delays and costs.

Features:

Hundreds of pages of detailed repair information, printable entire manual or specific sections, hundreds of photos and illustrations, clear numbered instructions, integrated electrical system diagnostics with wiring diagrams.

📋 Manual Details

Covered Styles:

All styles covered

Estimated Pages:

Hundreds of pages

Type:

Workshop Service Repair Manual

Language:

English

Format:

PDF Download

Delivery Method:

Instant download link provided on the checkout page immediately after payment completion.

📖 Manual Coverage

Covered Systems:

General Maintenance, Troubleshooting, Engine Service/Repair, Transmission Service/Repair, Brake System, Wiring Diagram, Electrical System, Suspension, Periodic Lubrication, Steering, Cooling System, Fuel Injection, Fuel System, Emission System, Heater/Air Conditioning, Engine Control System, Chassis/Body, Restraint System, Interior, Differential/Drive, Axle

Engine Service Repair:

Detailed procedures for engine overhaul, including cylinder head removal/installation, piston and connecting rod service, crankshaft service, camshaft maintenance, timing belt/chain service (if applicable), and component replacement (e.g., water pump, alternator).

Transmission Service Repair:

Comprehensive coverage for both manual and automatic transmissions, including clutch replacement, transmission fluid and filter changes, torque converter service, internal component diagnostics and repair, and complete transmission overhaul.

Brake System:

Detailed information on brake system components, including front and rear brake pad replacement, rotor service, brake caliper overhaul, hydraulic system bleeding, parking brake adjustments, and ABS system diagnostics.

Electrical System:

In-depth coverage of the vehicle's electrical system, including battery and charging system diagnostics, starter motor service, ignition system troubleshooting, lighting systems (headlights, taillights, interior), power windows, locks, mirrors, and audio system repair.

Wiring Diagram:

Crucial detailed wiring diagrams for all major electrical systems, allowing for accurate troubleshooting and repair of circuits, relays, fuses, and electronic modules. This is a significant value for diagnosing electrical issues.

Suspension:

Coverage of suspension components including struts, shock absorbers, control arms, ball joints, sway bars, and wheel bearings. Includes procedures for alignment specifications and component replacement.

Steering:

Detailed service procedures for the power steering system, including steering rack and pinion inspection and replacement, power steering pump service, and steering column components.

Cooling System:

Procedures for radiator service, coolant flushing and refilling, thermostat replacement, water pump maintenance, cooling fan operation and repair, and heater core service.

Fuel System:

Coverage of fuel tank service, fuel pump replacement, fuel filter maintenance, fuel line inspection, and fuel pressure testing. Includes details on the fuel injection system operation and diagnostics.

Emission System:

Information on emission control components, catalytic converter operation, oxygen sensors, evaporative emission control (EVAP) system, and exhaust gas recirculation (EGR) system diagnostics and repair.

Heater Air Conditional:

Detailed service and repair procedures for the HVAC system, including refrigerant handling (with appropriate safety warnings), compressor service, condenser and evaporator service, blower motor replacement, and climate control module diagnostics.

Chassis Body:

Procedures related to chassis components, body panel repairs, door and latch mechanisms, trunk and hood operation, glass replacement, and interior trim panel removal and installation.

Restraint System:

Information on the airbag system, including diagnostic procedures for airbag faults, seatbelt maintenance, and potential replacement of SRS components. Emphasizes safety precautions when working with the restraint system.

Interior:

Guidance on removing and reinstalling interior components such as dashboard elements, center consoles, door panels, headliner, and seating for access to underlying systems or for repair/replacement.

Differential Drive:

Procedures for servicing the front differential (if applicable, depending on driveline) and rear differential, including fluid checks and changes, seal replacements, and inspection of drive axles.

Axle:

Detailed procedures for servicing front and rear axles, including CV joint inspection and replacement, axle shaft removal and installation, and related seals and bearings.

Engine Control System:

Detailed coverage of the Powertrain Control Module (PCM), sensors (e.g., O2 sensors, MAF sensor, MAP sensor, crankshaft position sensor), actuators, and diagnostic trouble codes (DTCs) related to engine management and emissions.

Included Procedures:

Step-by-step instructions, detailed substeps, troubleshooting, electrical service procedures, component disassembly and reassembly, diagnostics

Troubleshooting:

Systematic troubleshooting guides to identify the root cause of common and complex problems, often presented in a flowchart format or as a symptom-based diagnostic procedure.

Maintenance:

Routine maintenance tasks such as oil changes, filter replacements, fluid level checks and top-offs, tire rotations, and spark plug replacement, with specified intervals and procedures.

Depth:

Complete disassembly, detailed illustrations, photos, and drawings, pinpoint critical information with notes, cautions, and warnings

Illustrations:

Hundreds of high-quality photographs, detailed drawings, and exploded views that visually guide the user through each repair or maintenance procedure, making complex tasks easier to understand.

Critical Information:

Emphasis on critical details through the inclusion of 'Notes,' 'Cautions,' and 'Warnings' boxes within each chapter, highlighting important safety information, potential pitfalls, and specific torque values or clearances.

📊 Manual Specifications

Format:

PDF

Compatibility:

Compatible with all PC-based Windows operating systems and Mac, ensuring broad accessibility. Requires Adobe PDF Reader.

Printability:

Printable without any restriction

Scalability:

Pages can be printed individually or as a complete manual, allowing users to create a physical copy tailored to their specific needs. High-resolution PDF ensures clear print output.

Binding:

N/A (Digital Download)

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Engine Options 2009:

The 2009 Mercury Milan was available with two primary engine options: a 2.3L DOHC 16-valve I-4 (Duratec) and a 3.0L DOHC 24-valve V6 (Duratec). The manual is expected to cover both.

Engine Code 2 3L:

Likely the 2.3L Duratec engine (code may vary, check manual for specifics). This engine shares components and design principles with other Ford Duratec engines of the era.

Engine Code 3 0L:

Likely the 3.0L Duratec V6 engine (code may vary, check manual for specifics). This V6 is known for its smooth operation and good torque delivery.

Engine Output Estimates:

2.3L I-4: Approximately 160 hp @ 6,200 rpm, 156 lb-ft @ 4,500 rpm. 3.0L V6: Approximately 203 hp @ 6,000 rpm, 207 lb-ft @ 4,800 rpm. (Specific outputs may vary by market/configuration).

Fuel Delivery:

Sequential Electronic Fuel Injection (SEFI)

🔧 Transmission

Standard Transmission:

For 2009, the 2.3L I-4 engine was typically paired with a 5-speed manual transmission or an optional 6-speed automatic transmission. The 3.0L V6 was exclusively offered with a 6-speed automatic transmission.

Optional Transmission:

6-speed automatic transmission (likely the 6F50/6F55 depending on engine and driveline)

Transmission Features:

The manual will cover the service and repair of both manual and automatic transmissions, including fluid changes, component diagnostics, and potential rebuild procedures.

📐 Dimensions

Wheelbase:

Approximately 107.4 inches (2728 mm)

Length:

Approximately 191.1 inches (4854 mm)

Width:

Approximately 72.2 inches (1834 mm)

Height:

Approximately 57.2 inches (1453 mm)

Curb Weight:

Varies by engine and trim, generally ranging from 3,200 to 3,500 lbs (1451 to 1588 kg)

🛡️ Safety Features

NHTSA Ratings 2009:

The 2009 Milan generally received good safety ratings. For example, it achieved 4 out of 5 stars in frontal driver and passenger crash tests and 5 out of 5 stars in side-impact tests from NHTSA in some configurations. (Specific ratings may vary by test and configuration).

Active Safety Features:

Anti-lock Braking System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC - AdvanceTrac with Roll Stability Control)

Passive Safety Features:

Front airbags, front side-impact airbags, front and rear side-curtain airbags (standard or optional depending on trim), front seatbelt pretensioners

💡 Technology Features

Infotainment System Availability:

Optional SiriusXM Satellite Radio, CD player, MP3 capability, and auxiliary audio input jack. Higher trims may have offered an upgraded audio system. The manual will detail the repair and diagnostics of these components.

Driver Assistance Features:

Cruise control is standard. Advanced driver assistance systems like adaptive cruise control or parking sensors were not widely available or standard on this model. The manual covers the operation and troubleshooting of systems like cruise control.

Connectivity Options:

Auxiliary audio input jack for connecting external devices. Bluetooth connectivity (Ford Sync) may have been an option on higher trims or later production runs, details would be in the manual.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 miles (12,000 km) or 6 months, using synthetic oil for optimal performance and longevity, but consult manual for specific recommendations based on driving conditions.

Engine Oil Type:

SAE 5W-20, meeting Ford specification WSS-M2C153-H or API Certified for gasoline engines. Consult the manual for exact capacity and viscosity recommendations for each engine.

Transmission Fluid Type Auto:

MERCON LV Automatic Transmission Fluid (ATF) or equivalent for the 6-speed automatic transmission. Consult manual for capacity and change intervals.

Coolant Type:

Ford Premium Engine Coolant (VC-7B) or equivalent, a 50/50 mixture of antifreeze and distilled water. Capacity varies by engine.

Brake Fluid Type:

DOT 3 or DOT 4 Motor Vehicle Brake Fluid. Consult the manual for the specific recommended type and capacity.

Power Steering Fluid Type:

Mercon V ATF or a specified power steering fluid. Manual will detail exact type and procedure for checking and topping off.

Differential Fluid Type:

Likely SAE 75W-90 GL-5 gear oil. Consult manual for specific capacity and change intervals for front/rear differentials.

Common Problems:

While generally reliable, common issues reported can include occasional transmission shifting problems, minor electrical gremlins, and wear on suspension components. The manual will provide diagnostic procedures for these and other potential issues.

📚 Vehicle History

Mercury Heritage:

Mercury was an automotive brand established by Ford in 1939, positioned as a premium competitor to Chevrolet and Plymouth. It was known for offering stylish and well-equipped vehicles, often with unique styling cues. The Mercury brand was retired in 2011.

Milan Evolution:

The Mercury Milan was introduced for the 2006 model year as a successor to the Mercury Mystique. It was based on Ford's CD3 platform, sharing its underpinnings with the Ford Fusion and Mazda 6. The 2009 model year saw a mid-cycle refresh with updated styling and features.

Production Location:

The Mercury Milan was manufactured at the Ford Flat Rock Assembly Plant in Flat Rock, Michigan, USA.