🏷️ Basic Information

Make:

Ford

Model:

Fusion Hybrid

Year:

2012

Product Name:

Ford Fusion Hybrid 2012 Service & Repair Workshop Manual

Broader Coverage Product Name:

Ford Vehicles All Models 2012 Service & Repair Workshop Manual Download PDF

👋 Introduction

Vehicle Segment:

Mid-size Sedan (Hybrid Variant)

Target Audience For Manual:

Professional Mechanics, Dealership Technicians, DIY Enthusiasts with advanced mechanical knowledge.

Key Competitors 2012:

Toyota Camry Hybrid, Honda Accord Hybrid, Hyundai Sonata Hybrid.

Visual Aid Quality:

Hundreds of pages with detailed photos and diagrams, including highly detailed exploded diagrams.

Instructional Style:

Step-by-step instructions for correct job completion.

📋 Manual Details

Overall Coverage:

All Ford models for the 2012 model year, with specific in-depth coverage for the Fusion Hybrid.

Estimated Page Count:

Hundreds of pages (exact number not specified, but implied to be extensive)

Type:

Factory Service Repair Workshop Manual

Language:

English

Format:

PDF (Downloadable)

📖 Manual Coverage

Powertrain:

Internal Combustion Engine (ICE), Electric Motor, Hybrid Powertrain Control Module (PCM), Battery Management System (BMS), Regenerative Braking System.

Chassis:

Suspension (front and rear), Steering System (electric power assisted), Brakes (hydraulic, ABS, EBD, regenerative braking integration), Wheel Alignment, Chassis Control Systems.

Electrical:

12V Electrical System, High-Voltage Battery System, Charging System, Lighting (exterior and interior), Instrumentation and Gauges, Audio System, HVAC System, Power Accessories (windows, locks, seats), Body Control Module (BCM), Powertrain Control Module (PCM), Hybrid Control Module (HCM), Antilock Braking System (ABS) module, Electronic Stability Control (ESC) module, Navigation System, Keyless Entry and Start System.

Body And Trim:

Exterior Body Panels, Interior Trim, Seats, Doors, Hood, Trunk, Bumpers, Glass, Roof Systems, Sealing Systems.

Hybrid Specific:

Hybrid Synergy Drive operation, High-Voltage Battery Pack (diagnosis, replacement procedures), Electric Motor/Generator (MG1/MG2) operation and diagnostics, Power Split Device (PSD) operation, Hybrid Control Module (HCM) programming and diagnostics, DC-DC Converter operation.

Maintenance:

Scheduled Maintenance (oil changes, filter replacements, fluid checks/changes), Brake Pad/Rotor Replacement, Tire Rotation and Balancing, Battery Checks (12V), Cabin Air Filter Replacement, Wiper Blade Replacement.

Repair:

Engine Repair and Rebuild, Transmission Repair, Hybrid Drivetrain Component Repair/Replacement, Brake System Overhaul, Suspension Component Replacement, Steering System Component Replacement, Electrical Component Diagnosis and Replacement, Body Panel Repair and Replacement, HVAC System Repair, Fuel System Repair (ICE).

Troubleshooting:

Diagnostic Trouble Codes (DTCs) interpretation and troubleshooting procedures, Symptom-based troubleshooting guides, Hybrid system fault diagnosis, Electrical system diagnostics, Engine performance issues, Transmission performance issues.

Diagnostics:

On-Board Diagnostics (OBD-II) systems, Scan Tool usage and data interpretation, Wiring Diagrams analysis, Component testing procedures (resistance, voltage, current), Hybrid system diagnostic tools and procedures.

Depth:

Comprehensive from basic maintenance to complete engine and hybrid system overhauls, including detailed electrical schematics and diagnostic procedures. Designed for professional technicians.

📊 Manual Specifications

File Type:

PDF

Searchability:

Implied to be searchable due to PDF format, allowing for quick access to information.

Printability:

Printable (single pages or entire manual).

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

License Type:

Lifetime use on unlimited devices. No expiry dates or renewal fees.

Operating Systems:

Compatible with all Windows and MAC computers.

⚙️ Engine Specifications

Ice Engine Type:

Atkinson Cycle, Inline 4-Cylinder

Ice Engine Displacement:

2.5 Liters (2488 cc)

Ice Engine Fuel Delivery:

Electronic Fuel Injection (EFI)

Ice Engine Horsepower Combined:

200 net horsepower (combined system output, ICE + electric motor)

Ice Engine Torque Combined:

Not explicitly stated for combined system, but ICE typically around 170 lb-ft.

Engine Code Typical:

Ford Duratec Hybrid (Hybrid variant of the 2.5L Duratec)

Electric Motor Type:

Permanent Magnet AC Synchronous Motor

High Voltage Battery Type:

Nickel-Metal Hydride (NiMH)

High Voltage Battery Voltage Nominal:

Approximately 300-350 Volts (DC)

Fuel Type:

Unleaded Gasoline

Fuel Tank Capacity:

17.5 gallons (approximate)

🔧 Transmission

Type:

Electronic Continuously Variable Transmission (eCVT) with integrated Power Split Device (PSD)

Optional Transmission:

N/A (Hybrid models are exclusively eCVT)

Hybrid Integration:

Seamless integration of ICE and electric motor via the PSD for optimal efficiency and performance.

Fluid Type Transmission:

Mercon LV ATF or equivalent (Specific Ford MERCON LV specification required for eCVT, consult manual for exact part numbers and fill procedures).

📐 Dimensions

Length:

190.9 inches

Width:

72.9 inches

Height:

58.2 inches

Wheelbase:

107.4 inches

Curb Weight:

Approximately 3,598 lbs

Trunk Capacity:

16.0 cubic feet

🛡️ Safety Features

NHTSA Overall Rating:

Likely 5-Star (Based on typical Ford Fusion ratings for the era, specific 2012 Fusion Hybrid rating should be verified in a comprehensive safety document if available).

IIHS Top Safety Pick:

Likely a Top Safety Pick (Based on typical Ford Fusion ratings for the era, specific 2012 Fusion Hybrid rating should be verified in a comprehensive safety document if available).

ABS:

Anti-lock Braking System (ABS) with Electronic Brake-force Distribution (EBD) and Brake Assist.

Esc:

Electronic Stability Control (ESC)

Traction Control:

Traction Control System (TCS)

Airbags Front:

Dual-stage front airbags for driver and passenger.

Airbags Side:

Front side-impact airbags.

Airbags Curtain:

Front and rear side-curtain airbags.

Seatbelts:

Front seat pretensioners and load limiters, Rear seat LATCH (Lower Anchors and Tethers for Children) system.

💡 Technology Features

Infotainment System Typical:

Ford SYNC infotainment system (voice-activated communication and entertainment system).

Audio Features:

AM/FM stereo, CD player, MP3 capability, auxiliary audio input, SiriusXM Satellite Radio (subscription required).

Features Available:

Rear parking sensors, rearview camera (on some trims/packages).

Connectivity Features:

Bluetooth connectivity for hands-free calling and audio streaming, USB port for device connection.

Driving Modes:

EV (Electric Vehicle) mode, ECO mode, Sport mode (as part of overall powertrain management).

🔧 Maintenance

Oil Change Interval:

Every 7,500 miles or 12 months, whichever comes first (using synthetic blend or full synthetic oil). Consult manual for exact intervals based on driving conditions.

Engine Air Filter:

Inspect every 15,000 miles, replace as needed. Recommended replacement interval typically around 30,000 miles.

Cabin Air Filter:

Inspect every 15,000 miles, replace as needed. Recommended replacement interval typically around 20,000-30,000 miles.

Coolant Change Interval:

Initial change at 100,000 miles, then every 50,000 miles thereafter. Use Ford Super Coolant, VC-12-A (or equivalent specified in manual).

Engine Oil Type:

SAE 5W-20 Full Synthetic Motor Oil (Ford specified)

Engine Oil Capacity:

5.7 quarts (with filter)

Brake Fluid Type:

DOT 3

Common Complaints 2012 Fusion Hybrid:

Occasional reports of HVAC system issues (compressor, blend doors), minor electrical gremlins, and potential battery degradation over extended lifespan (though generally reliable).

Hybrid Specific Concerns:

While the hybrid system is robust, diagnosis of the high-voltage battery pack or power control module requires specialized equipment and knowledge, fully covered by this manual.

📚 Vehicle History

Ford Hybrid History:

Ford has been a significant player in hybrid technology, introducing models like the Escape Hybrid and continuing development into sedans like the Fusion Hybrid.

Fusion Hybrid Introduction:

The Ford Fusion Hybrid was introduced in the North American market in late 2009 for the 2010 model year, evolving into the second generation for 2013.

Generation Covered:

This manual covers the first generation Ford Fusion Hybrid (2010-2012 model years).

Manufacturing Location Typical:

Hermosillo, Mexico (for North American market).

🏆 Awards & Recognition

Fuel Economy Awards:

The Ford Fusion Hybrid has historically been recognized for its excellent fuel efficiency, often receiving accolades from automotive publications.