🏷️ Basic Information

Make:

Ford

Model:

Fusion

Model Years Covered:

2010, 2011, 2012

Engine Options Covered:

2.5L Duratec, 3.0L Duratec V6, 3.5L Duratec V6, Hybrid

Vin Code Generation:

Fusion (CD391 platform for 2010-2012 models)

👋 Introduction

Segment:

Mid-size sedan

Target Audience:

Families, commuters, individuals seeking a comfortable and efficient sedan.

Key Competitors:

Toyota Camry, Honda Accord, Chevrolet Malibu, Nissan Altima.

Distinguishing Features:

Available V6 engines (3.0L, 3.5L), and a segment-leading hybrid variant. Known for its comfortable ride and interior space.

Powertrain Options:

Variety of efficient and powerful engine options catering to different needs.

Hybrid Technology:

Early adoption of hybrid technology for improved fuel economy.

Comfort And Features:

Generally well-equipped interiors with a focus on passenger comfort.

Diy Advantage:

Enables significant cost savings on maintenance and repairs through detailed, user-friendly instructions.

📋 Manual Details

Coverage Summary:

All repair and service procedures, all models, engines, trim levels, and transmission types.

Page Count:

Estimated 2500+ pages (typical for complete workshop manuals of this era)

Manual Type:

Complete Workshop Service Repair Manual

Language:

English

Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine Mechanical:

Engine assembly, disassembly, cylinder head, pistons, connecting rods, crankshaft, camshafts, timing, lubrication system, cooling system, fuel injection, ignition system, exhaust system, emission controls.

Hybrid Powertrain:

Hybrid system operation, high-voltage battery, electric motor, power control module, regenerative braking, engine integration.

Transmission Drivetrain:

Automatic transmission (e.g., 6F50/6F55), manual transmission (if applicable), transaxle, drive shafts, CV joints, differentials.

Chassis Suspension:

Front suspension, rear suspension, shock absorbers, struts, control arms, bushings, wheel bearings, steering system (power steering, rack and pinion).

Brakes:

Front brakes (disc), rear brakes (disc), parking brake, Anti-lock Braking System (ABS), Electronic Brake-force Distribution (EBD), brake fluid specifications.

Electrical System:

Battery, charging system (alternator), starting system, lighting system, instrument cluster, power windows, power locks, wipers, horn, fuses, relays, wiring diagrams.

Climate Control:

Air conditioning system, heater, ventilation, blower motor, refrigerant, HVAC components.

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass, mirrors, sunroof, trim, exterior lighting.

Body Interior:

Dashboard, seats, upholstery, interior trim, airbags, seat belts, interior lighting.

Diagnostics Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting, diagnostic strategies, connector pinouts.

Routine Maintenance:

Oil changes, filter replacements (oil, air, cabin), fluid checks and top-offs, tire rotation, spark plug replacement, battery testing.

Engine Repairs:

Head gasket replacement, piston ring replacement, bearing replacement, valve stem seal replacement, timing belt/chain service, component replacement (alternator, starter, water pump).

Hybrid Component Service:

High-voltage battery coolant service, electric motor inspection, power control module diagnostics and replacement.

Transmission Service:

Transmission fluid and filter changes, transmission removal and installation, torque converter service, solenoid replacement.

Suspension Steering Repair:

Shock/strut replacement, control arm bushing replacement, ball joint replacement, tie rod end replacement, power steering pump/rack service.

Brake System Overhaul:

Brake pad and rotor replacement, caliper service, brake line replacement, ABS module diagnostics.

Electrical Diagnostics Repair:

Wiring harness repair, sensor testing and replacement, module programming, charging system diagnosis, starter motor replacement.

HVAC System Repair:

Refrigerant recharge, compressor replacement, evaporator/condenser service, blend door actuator replacement.

Body Panel Replacement:

Fender replacement, door hinge adjustment/replacement, trunk lid repair, bumper cover installation.

Airbag System Service:

Airbag module replacement, seat belt pre-tensioner replacement, SRS system diagnostics.

Depth Level:

Comprehensive (from basic maintenance to complete engine and transmission rebuilds, including advanced diagnostics).

Diagnostic Capabilities:

Detailed troubleshooting trees, DTC explanations, component testing procedures, wiring diagrams for electrical systems.

Rebuild Procedures:

Step-by-step instructions for engine, transmission, and component disassembly, inspection, repair, and reassembly.

Specifications Tolerances:

Precise torque specifications, critical clearances, material specifications, fluid capacities, and performance data.

📊 Manual Specifications

File Format:

PDF (Portable Document Format)

Searchability:

Text-searchable PDF for quick information retrieval.

Print Quality:

High-resolution, suitable for printing individual pages or entire sections.

Binding Type:

N/A (Downloadable, binding determined by user printing)

Paper Type:

N/A (Digital format, print quality depends on user's printer)

⚙️ Engine Specifications

2.5L Duratec:

Inline-4 cylinder, DOHC, 16-valve. Horsepower: ~175 hp @ 6000 rpm. Torque: ~170 lb-ft @ 4500 rpm. Fuel System: Electronic Fuel Injection (EFI).

3.0L Duratec V6:

V6 cylinder, DOHC, 24-valve. Horsepower: ~221 hp @ 6250 rpm. Torque: ~210 lb-ft @ 4500 rpm. Fuel System: Electronic Fuel Injection (EFI).

3.5L Duratec V6:

V6 cylinder, DOHC, 24-valve. Horsepower: ~263 hp @ 6250 rpm. Torque: ~249 lb-ft @ 4500 rpm. Fuel System: Electronic Fuel Injection (EFI).

Hybrid:

2.5L Atkinson Cycle I4 combined with an electric motor. System Net Horsepower: ~191 hp. System Net Torque: Varies. Fuel System: Electronic Fuel Injection (EFI).

Fuel Type Required:

Unleaded gasoline (87 octane minimum recommended for 2.5L and 3.0L; 91 octane recommended for 3.5L for optimal performance). Hybrid system uses regular unleaded.

Hybrid Battery Type:

Nickel-metal-hydride (NiMH) for 2010-2012 models.

🔧 Transmission

Standard Transmission Type:

6-speed automatic transmission (e.g., 6F50 on 2.5L, 6F55 on V6 models).

Optional Transmission Type:

Hybrid Transaxle with integrated electric motor.

Transmission Fluid Type:

Refer to specific engine/transmission application, typically Mercon V or equivalent for automatic transmissions. Specific hybrid fluid for hybrid models.

📐 Dimensions

Length:

Approx. 191.8 inches

Width:

Approx. 72.2 inches

Height:

Approx. 57.1 inches

Wheelbase:

Approx. 107.4 inches

Curb Weight Range:

Approx. 3500 - 4000 lbs depending on engine and options (Hybrid model approx. 3800 lbs).

🛡️ Safety Features

NHTSA Overall Safety Rating:

Typically rated 4 or 5 stars by NHTSA for the generation.

IIHS Top Safety Pick:

Often awarded as an IIHS Top Safety Pick for its model years.

Active Safety Systems:

Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control System (TCS), available Blind Spot Monitoring (on some trims).

Passive Safety Features:

Front airbags (driver, passenger), front side airbags, side curtain airbags, seat belt pretensioners.

💡 Technology Features

Infotainment System:

SYNC infotainment system with voice recognition, Bluetooth connectivity, available navigation system, SiriusXM Satellite Radio.

Audio Options:

Standard audio system, available premium Sony audio system.

Driver Assistance Features:

Available rearview camera, Blind Spot Information System (BLIS), Adaptive Cruise Control (ACC) on some higher trims.

Connectivity Options:

USB port for media playback and device charging, Bluetooth for hands-free calling and audio streaming.

🔧 Maintenance

Oil Change Interval:

Typically every 7,500 miles or 6 months (using synthetic blend or full synthetic oil), consult manual for exact type and interval based on driving conditions.

Engine Air Filter Replacement:

Recommended every 30,000 miles or as needed based on inspection.

Cabin Air Filter Replacement:

Recommended every 15,000-30,000 miles or annually.

Transmission Fluid Change Interval:

Typically every 60,000-100,000 miles for automatic transmissions, or as indicated by the manual, especially for severe duty.

Engine Oil Spec:

SAE 5W-20 (API Certified, ILSAC GF-5 compatible). Check owner's manual for specific engine variant requirements.

Coolant Spec:

Ford Premium Engine Coolant (Yellow) or equivalent (50/50 mix with distilled water). Hybrid system uses a specific coolant.

Brake Fluid Spec:

DOT 3 brake fluid.

Common Problems 2.5L:

Occasional intake manifold runner issues, PCV valve problems leading to oil consumption.

Common Problems V6:

Variable intake manifold problems, potential issues with coolant leaks from intake gaskets or water pump.

Common Problems Hybrid:

Hybrid battery longevity concerns (though generally robust for this period), occasional issues with the power inverter coolant pump.

Common Problems General:

Transmission solenoid issues, electronic throttle body problems, power steering pump noise.

📚 Vehicle History

Ford Sedan Legacy:

Ford has a long history of producing popular sedans, continuing with the Fusion's success as a modern global platform.

Generation Focus:

This manual covers the first generation Ford Fusion (CD391), which debuted for the 2006 model year and received significant updates for 2010, including refreshed styling and updated powertrains, notably the introduction of the hybrid model.

Manufacturing Location:

Hermosillo, Mexico

🏆 Awards & Recognition

IIHS Awards:

Multiple models within this generation earned the Insurance Institute for Highway Safety (IIHS) Top Safety Pick designation.

Consumer Digest Best Buy:

Ford Fusion has been recognized as a Consumer's Digest Best Buy in various configurations during its production run.

Green Car Ofthe Year:

The Ford Fusion Hybrid was a strong contender and often recognized for its advancements in fuel efficiency and environmental impact.