Ford Fusion & Fusion Hybrid Complete Workshop Service Repair Manual 2012

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🏷️ Basic Information Identification Make: Ford Model: Fusion Model Variant: Fusion Hybrid Year: 2012 Generation Generation Designation: First Generation (CD340) Generation Years: 2006-2012 Codes Platform Code: CD340 👋 Introduction Market...

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Art.-Nr: 206479

Stichworte: 2012 Car Cars Ford Fusion Fusion Hybrid

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Beschreibung

🏷️ Basic Information

Identification

Make:

Model:

Fusion

Model Variant:

Fusion Hybrid

Year:

Generation

Generation Designation:

First Generation (CD340)

Generation Years:

2006-2012

Codes

Platform Code:

CD340

👋 Introduction

Market Position

Segment:

Mid-size Sedan

Positioning Statement:

The Ford Fusion offered a compelling blend of stylish design, comfortable interior, and available hybrid powertrain, competing effectively against established players like the Toyota Camry and Honda Accord.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Chevrolet Malibu, Hyundai Sonata

Key Features

Design:

European-inspired styling, distinct grille, sleek profile

Powertrain Options:

Efficient gasoline engines and a highly regarded hybrid variant

Interior:

Spacious and well-appointed cabin, user-friendly controls

📋 Manual Details

Coverage Areas

Engine Coverage:

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

Transmission Coverage:

6-Speed Automatic (6F35), Continuously Variable Transmission (CVT) for Hybrid

Trim Coverage:

S, SE, SEL, Sport, Hybrid

Page Count

Estimated Page Count:

2000+

Manual Type

Type:

Workshop Service Repair Manual

Language

Language:

English

Format

Format:

Digital Download (PDF)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, diagnosis, component testing, cooling system, lubrication system, fuel delivery, ignition system (gasoline), hybrid powertrain components

Transmission:

Automatic transmission overhaul, CVT operation and repair, clutch systems, torque converter, shift controls, diagnosis

Brakes:

Hydraulic system, ABS/ESP system, brake pads, rotors, calipers, parking brake, hybrid regenerative braking system

Electrical:

Battery, charging system, starting system, lighting, wiring diagrams, fuses, relays, body control modules, instrument cluster, power windows/locks/mirrors

Suspension:

Front and rear suspension components, struts, shocks, control arms, ball joints, bushings, alignment specifications

Steering:

Power steering system (hydraulic and electric assist), steering rack, tie rods, steering column

HVAC:

Air conditioning system, heater core, blower motor, climate control module, refrigerant charging procedures

Body And Frame:

Body panel repair, interior trim, exterior trim, chassis components, welding procedures

Hybrid Specific:

High-voltage battery system, electric motor, power control module, charging system (DC-DC), hybrid system diagnosis and safety precautions

Procedures Included

Maintenance:

Oil change, filter replacement, fluid level checks, coolant flush, brake fluid flush, spark plug replacement, belt replacement

Troubleshooting:

Diagnostic trouble codes (DTCs), symptom-based troubleshooting guides, electrical system diagnostics

Repair:

Engine component replacement (e.g., pistons, valves, head gasket), transmission rebuilds, brake caliper replacement, suspension component replacement, hybrid component repair

Installation:

Accessory installation, component replacement procedures

Technical Depth

Depth:

Comprehensive (A-Z), from basic maintenance to complete engine and transmission overhauls, including detailed diagnostic procedures and wiring diagrams

📊 Manual Specifications

File Format

File Type:

Searchable:

Print Quality

Quality:

High resolution, suitable for printing

Printable:

Yes (individual pages or full document)

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Software Requirements

Required Software:

Adobe Reader (or compatible PDF reader)

⚙️ Engine Specifications

Primary Engine

Engine 1:

2.5L Duratec DOHC I4

Engine 1 Horsepower:

175 hp @ 6000 rpm

Engine 1 Torque:

170 lb-ft @ 4500 rpm

Engine 2:

3.0L Duratec 30 V6 DOHC

Engine 2 Horsepower:

240 hp @ 6500 rpm

Engine 2 Torque:

222 lb-ft @ 4300 rpm

Engine 3:

3.5L Duratec 35 V6 DOHC

Engine 3 Horsepower:

263 hp @ 6250 rpm

Engine 3 Torque:

249 lb-ft @ 4500 rpm

Engine Hybrid:

2.5L Atkinson Cycle I4 Hybrid (Ford's Hybrid Technology Package)

Engine Hybrid System Net Horsepower:

191 hp

Fuel System

Fuel Type:

Unleaded Gasoline (87 Octane Recommended); Hybrid uses Atkinson Cycle gasoline

Fuel Delivery:

Electronic Fuel Injection (EFI)

Performance

Emissions Compliance:

Meets EPA and California LEV II standards

🔧 Transmission

Standard

Transmission Gasoline:

6-Speed Automatic (6F35)

Optional

Transmission Hybrid:

Electronically Controlled Continuously Variable Transmission (eCVT)

Features

Transmission Features:

SelectShift™ Automatic, Grade Assist, Manual Mode (on some models)

Fluid Specifications

Automatic Transmission Fluid Type:

Mercon® LV Automatic Transmission Fluid

Cvt Fluid Type:

Specific CVT Fluid (refer to manual for exact specification)

📐 Dimensions

Exterior

Length:

190.6 inches (4841 mm)

Width:

72.4 inches (1839 mm)

Height:

58.1 inches (1476 mm)

Wheelbase:

107.4 inches (2728 mm)

Weights

Curb Weight Gasoline Approx:

3,400 - 3,600 lbs (1542 - 1633 kg)

Curb Weight Hybrid Approx:

3,700 lbs (1678 kg)

Cargo

Trunk Volume Gasoline:

16.5 cubic feet (467 L)

Trunk Volume Hybrid:

13.0 cubic feet (368 L) (due to battery pack)

🛡️ Safety Features

Ratings

NHTSA Overall Rating 2012:

5-Star (Overall)

IIHS Top Safety Pick:

Yes (for 2012)

Active Features

Standard

Traction Control:

Standard

Electronic Stability Control:

Standard (AdvanceTrac™)

Passive Features

Airbags:

Front, front-side, and side-curtain airbags

💡 Technology Features

Infotainment

Infotainment System:

Available SYNC® infotainment system with voice recognition, Bluetooth connectivity, and optional navigation.

Audio Options:

Various audio systems, including premium Sony® branded systems on higher trims.

Driver Assistance

Available Features:

Blind Spot Information System (BLIS), Cross-Traffic Alert, Rearview Camera.

Connectivity

Connectivity Options:

USB ports, auxiliary audio input, SYNC services (for emergency assistance and information).

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 to 7,500 miles or 6 months, depending on driving conditions (refer to manual for specific recommendations).

Engine Oil Filter Replacement:

Recommended with every oil change.

Engine Air Filter Replacement:

Every 15,000 to 30,000 miles or as needed.

Cabin Air Filter Replacement:

Every 10,000 to 15,000 miles or once a year.

Coolant Flush:

Every 30,000 to 100,000 miles or 5 years, depending on coolant type.

Brake Fluid Flush:

Every 2 to 3 years or 45,000 miles.

Spark Plug Replacement Gasoline:

Typically around 100,000 miles for iridium spark plugs.

Fluid Specifications

Engine Oil Type 2 5L 3 0L:

SAE 5W-20 (API SN or ILSAC GF-5 certified)

Engine Oil Type 3 5L V6:

SAE 5W-30 (API SN or ILSAC GF-5 certified)

Engine Oil Capacity 2 5L:

4.5 quarts (4.3 L) with filter change

Engine Oil Capacity 3 0L V6:

5.5 quarts (5.2 L) with filter change

Engine Oil Capacity 3 5L V6:

6.0 quarts (5.7 L) with filter change

Coolant Type:

Motorcraft® Yellow Premium Engine Coolant (Ford specification WSS-M97B44-D)

Known Issues

Common Issues List:

Transmission shudder/slipping (6F35), fuel pump failures, water pump leaks, power steering pump issues (hydraulic systems), HVAC blower motor failures, potential for coolant leaks from crossover pipes.

Hybrid Specific Concerns:

Occasional reports of hybrid battery cooling fan issues, high-voltage system warning lights (often related to connections or sensors).

📚 Vehicle History

Brand Heritage

Ford Heritage:

Ford Motor Company, a global automotive manufacturer, has a history dating back to 1903, known for innovation and mass production.

Model Evolution

Fusion Introduction:

Introduced for the 2006 model year, the Ford Fusion replaced the Ford Mondeo in North America as Ford's mid-size sedan offering.

First Generation Facelift:

The 2010 model year saw a significant facelift, introducing Ford's new corporate grille and updated styling, with the hybrid model debuting for 2010.

Production

Manufacturing Location:

Ford's Hermosillo Stamping and Assembly Plant in Hermosillo, Sonora, Mexico

Production Years:

2006-2012 (First Generation)

🏆 Awards & Recognition

Recognitions

Award 1:

IIHS Top Safety Pick

Award 2:

Consumers Digest 'Best Buy' (for certain configurations/model years)

Ratings

Kl Customer Satisfaction Index:

Generally competitive for its segment.