Target Audience:
DIY car owners, independent repair shops, enthusiasts
Competitors:
Toyota Camry, Honda Accord, Nissan Altima, Chevrolet Malibu, Chrysler Sebring/200
Value Proposition:
Significant cost savings on repairs and maintenance, empowerment for vehicle owners
Ease Of Use:
Step-by-step instructions with pictures
Coverage:
All models, engines, trim levels, and transmission types
Estimated Page Count:
Extensive (exact number not specified, but described as 'complete' and covering A-Z)
Type:
Workshop Service Repair Manual
Format:
Downloadable Digital Format (PDF compatible)
Powertrain:
Engine (2.3L Duratec, 3.0L Duratec, 2.5L Duratec), Transmission (5-speed Manual, 6-speed Automatic, CVT for Hybrid)
Chassis:
Suspension (Front McPherson Strut, Rear Multi-link), Steering (Hydraulic Power Steering), Brakes (Front Ventilated Disc, Rear Solid Disc; ABS, EBD, Traction Control)
Electrical:
Battery, Charging System, Starting System, Ignition System, Lighting, Instrumentation, Powertrain Control Module (PCM), Body Control Module (BCM), HVAC Controls, Audio System, Power Accessories (Windows, Locks, Mirrors), Safety Systems (Airbags, Seatbelts)
Body:
Exterior Body Panels, Doors, Hood, Trunk, Bumpers, Glass, Interior Trim, Seats, Headliner
Maintenance:
Scheduled maintenance, fluid changes, filter replacements, inspections
Repair:
Engine overhaul, transmission repair, brake system overhaul, suspension component replacement, electrical component diagnosis and replacement, body panel repair
Diagnostics:
Troubleshooting guides, symptom-based diagnostics, diagnostic trouble codes (DTCs) interpretation
Technical Specifications:
Torque specifications, clearances, wiring diagrams, diagnostic connector locations, component identification
Depth:
Comprehensive: from basic maintenance to in-depth component repair and system diagnostics
Engine 1:
2.3L DOHC Inline-4 Duratec (MZR)
Engine 1 Power:
Approx. 160 hp @ 6200 rpm
Engine 1 Torque:
Approx. 150 lb-ft @ 4500 rpm
Engine 2:
3.0L DOHC V6 Duratec
Engine 2 Power:
Approx. 221 hp @ 6250 rpm
Engine 2 Torque:
Approx. 200 lb-ft @ 4800 rpm
Engine 3:
2.5L DOHC Inline-4 Duratec (US Market)
Engine 3 Power:
Approx. 175 hp @ 6000 rpm
Engine 3 Torque:
Approx. 170 lb-ft @ 4500 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Coolant Type:
Ford Premium Engine Coolant (Green) or equivalent meeting WSS-M97B44-D specification
Transmission 1:
5-speed Manual Transmission (Getrag MMT6, typically with 2.3L and 2.5L engines)
Transmission 2:
5-speed Automatic Transmission (AxleTech 5F50, typically with 2.3L and 3.0L engines)
Transmission 3:
6-speed Automatic Transmission (6F50, typically with 3.0L V6 engines, later models)
Transmission Hybrid:
Continuously Variable Transmission (CVT) for Fusion Hybrid (2010-2012)
Automatic Transmission Fluid:
Mercon V (for 5F50, 6F50) or Mercon LV (for specific later 6F50 applications - manual will specify exact requirement)
Manual Transmission Fluid:
Gear Oil API GL-4, SAE 75W-90 (check manual for specific Ford specification)
Length:
Approx. 191.7 inches (4869 mm)
Width:
Approx. 72.2 inches (1834 mm)
Height:
Approx. 57.2 inches (1453 mm)
Wheelbase:
Approx. 107.4 inches (2728 mm)
Trunk Volume:
Approx. 16.0 cubic feet (453 liters)
Curb Weight:
Approx. 3200-3500 lbs (1450-1590 kg), depending on engine and trim
NHTSA Front Impact Driver:
Good (for models equipped with side airbags and ABS)
NHTSA Front Impact Passenger:
Good
NHTSA Side Impact Front Seat:
Good
NHTSA Side Impact Rear Seat:
Good
IIHS Roof Strength:
Good (for applicable models)
ABS:
Standard Anti-lock Braking System
Traction Control:
Standard or Optional Electronic Traction Control (TCS)
Stability Control:
Optional Electronic Stability Control (ESC) on some models
Airbags:
Frontal airbags (driver/passenger), front side-impact airbags, side curtain airbags (optional or standard depending on trim/year)
Available System:
Ford SYNC (optional, introduced in later years), AM/FM/CD/MP3 audio system, optional SiriusXM Satellite Radio.
Optional Features:
Reverse sensing system, backup camera (late models/optional).
Sync Features:
Voice-activated control of audio and phone (requires compatible phone and Bluetooth).
Oil Change Interval:
Typically 5,000 miles (8,000 km) or 6 months, whichever comes first, under normal driving conditions. Severe driving conditions may require 3,000 miles (5,000 km) or 3 months.
Engine Air Filter:
Replace every 30,000 miles (48,000 km) or as needed based on inspection.
Cabin Air Filter:
Replace every 15,000 miles (24,000 km) or annually, or as needed based on inspection.
Spark Plugs:
Iridium spark plugs typically last 100,000 miles (160,000 km). Consult manual for exact type and interval.
Engine Oil Capacity 2.3L:
Approx. 4.5 quarts (4.3 liters) with filter, SAE 5W-20
Engine Oil Capacity 3.0L:
Approx. 5.0 quarts (4.7 liters) with filter, SAE 5W-20
Engine Oil Capacity 2.5L:
Approx. 4.5 quarts (4.3 liters) with filter, SAE 5W-20
Coolant Capacity:
Approx. 7.1-7.5 quarts (6.7-7.1 liters) depending on engine.
Power Steering Pump:
Occasional reports of premature failure of the hydraulic power steering pump.
Transmission Hesitation:
Some drivers report occasional hesitation or rough shifting with the automatic transmissions, particularly the 5-speed unit.
HVAC Blend Door Actuator:
Common issue across many Ford models of this era, where the blend door actuator can fail, leading to temperature control problems.
Engine Mounts:
Wear on engine mounts can lead to increased vibration felt in the cabin.
Ford Sedan History:
Ford has a long history of producing popular sedans, from the Falcon and Fairlane to the Taurus and Focus. The Fusion was designed to capitalize on the growing mid-size sedan market with a blend of European styling influences and American practicality.
Fusion Gen1 Design:
The first generation Ford Fusion (2006-2012) was a significant departure for Ford, built on the Mazda-derived CD3 platform. It aimed to offer a more refined driving experience and stylish European-inspired design compared to its predecessors.
Mid Cycle Refresh:
A mid-cycle refresh occurred for the 2010 model year, featuring updated front and rear styling, improved interior materials, and the introduction of the 2.5L Duratec engine and the Fusion Hybrid model.
Assembly Location:
Hermosillo, Sonora, Mexico
Production Years Global:
2005–2012
Consumer Reports:
Received varied reliability ratings from Consumer Reports over its production run, often praised for driving dynamics and styling but sometimes flagged for specific mechanical issues.
Edmunds Reviews:
Often cited by automotive reviewers for its sharp handling, stylish interior, and good value proposition within the mid-size segment.
