🏷️ Basic Information

Make:

Ford

Model:

Fusion Hybrid

Model Generation:

First Generation (CD391)

Model Years Covered:

2010, 2011, 2012, 2013

Platform Code:

CD391

👋 Introduction

Target Audience:

Professional mechanics, dealership technicians, and experienced DIY car owners

Value Proposition:

Provides comprehensive, dealer-level repair information to save on professional service costs.

Digital Accessibility:

Instantly accessible on any device with PDF reader, no waiting for physical delivery.

Searchability And Navigation:

Well-structured content with bookmarks for efficient navigation and information retrieval.

Accuracy And Detail:

Detailed instructions and high-definition diagrams ensure accurate repairs.

📋 Manual Details

Manual Coverage Scope:

Comprehensive Workshop Service and Repair

Geographic Coverage:

Primarily North American market specifications, but broadly applicable to global models with potential regional variations.

Page Count:

> 6800

Manual Type:

Workshop Service and Repair Manual / Owner's Manual

Language:

English

Digital Format:

PDF

📖 Manual Coverage

Engine Systems:

2.5L Duratec 25 I4, 3.0L Duratec 30 V6, 3.5L Duratec 35 V6, 2.5L Duratec 25 Hybrid (including Atkinson cycle operation)

Hybrid System:

High-voltage battery, electric motor-generators, power control unit, hybrid control module, regenerative braking system

Transmission Systems:

Manual Transmission, Aisin AW21 Automatic Transmission, 6F35 Automatic Transmission, e-CVT (Electronically Controlled Continuously Variable Transmission)

Drivetrain:

Driveline, Driveshaft, Axles, Differentials, Transfer Case System (if applicable to specific AWD variants), 4WD System (if applicable)

Chassis And Suspension:

Suspension System (front and rear), Wheels, Tires, Steering, Power Steering, Steering Column and Switches

Brakes:

Brake System, Parking Brakes, Hydraulic Brakes, Power Brake System, Anti-lock Brakes (ABS), Electronic Brake-force Distribution (EBD)

Body And Interior:

Body Panels System, Interior & Exterior Trim, Mirrors, Seats, Glass & Frame, Instrument Panel, Lock & Entry System, Wiper & Washer, Roof Panel, Body Repair, Body Mounting System

Electrical And Electronics:

Starting System, Charging System, Battery, Mounting & Cables, Ignition System, Emission Control, Evaporative Emission, Engine Control System, Instrument Cluster, Lighting System, Horn, Parking Aid, Entertainment System, Communication Network, Anti-theft System, Remote Convenience, Cruise Control System, Multifunction Electronics

Climate Control:

Climate Control System

Safety And Restraint:

Safety Belt System, Restraint System (Airbags)

Emission Control Systems:

Catalytic converter, oxygen sensors, evaporative emission control (EVAP) system

Fuel Charging And Control:

Fuel tank, fuel pump, fuel injectors, fuel pressure regulation

Accessory Drive:

Serpentine belt system, accessory pulleys, tensioners

Intake Air System:

Air filter, air intake manifold, mass air flow sensor

Exhaust System:

Exhaust manifold, catalytic converter, muffler, exhaust pipes

Acceleration System:

Throttle body, accelerator pedal position sensor

Repair Procedures:

Complete diagnostic procedures, component removal and installation, system repair and overhaul

Maintenance Procedures:

Periodic maintenance, fluid changes, filter replacements, inspections, lubrication

Diagnostic Procedures:

Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics

Specification Data:

Torque specifications, electrical schematics, wiring diagrams, component data

Electrical Schematics Coverage:

Detailed wiring diagrams for all vehicle systems, including powertrain, body, chassis, and infotainment.

Troubleshooting Charts:

Extensive symptom-based troubleshooting charts to aid in diagnosing issues.

Component Replacement Guides:

Step-by-step guides for replacing major and minor components.

Depth Of Coverage:

Professional-level diagnostics and repair, suitable for both experienced technicians and DIY enthusiasts

Diagnostic Tool Requirements:

Information relevant to using Ford's diagnostic scan tools (e.g., IDS) for advanced diagnostics.

Rebuild Procedures:

Detailed procedures for engine and transmission rebuilds where applicable.

📊 Manual Specifications

File Type:

Compressed ZIP archive containing PDF files

Required Software:

Adobe Acrobat Reader, WinZip/WinRAR (for extraction)

Digital File Size:

188 MB

Printability:

Printable pages

Diagram Quality:

High Definition

Binding Method:

Not Applicable (Digital)

Paper Quality:

Not Applicable (Digital)

⚙️ Engine Specifications

Engine Options:

2.5L Duratec 25 I4, 3.0L Duratec 30 V6, 3.5L Duratec 35 V6, 2.5L Duratec 25 Hybrid

Engine Type Hybrid:

Atkinson Cycle I4 with Electric Motor Assistance

Fuel Delivery Hybrid:

Electronic Fuel Injection (EFI)

Engine Management System:

Powertrain Control Module (PCM) / Hybrid Control Module (HCM)

Hybrid System Architecture:

Ford's hybrid system integrates a gasoline engine with electric motor-generators for enhanced fuel economy and performance.

🔧 Transmission

Standard Transmission:

e-CVT for Hybrid Models

Optional Transmissions:

Manual Transmission, Aisin AW21 Automatic, 6F35 Automatic

Hybrid Transmission Type:

Electronically Controlled Continuously Variable Transmission (e-CVT) with integrated electric motor-generators

Automatic Transmission Fluid:

Specific Automatic Transmission Fluid (ATF) types required for AW21 and 6F35 (refer to manual for exact specifications)

📐 Dimensions

Body Styles:

4-Door Sedan

Curb Weight Range:

Approx. 3,600 - 4,000 lbs (depending on powertrain and options)

🛡️ Safety Features

NHTSA Safety Ratings:

Likely achieved high safety ratings (e.g., 5-star) during its model run; specific ratings to be confirmed within manual.

Active Safety Systems:

Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control System (TCS), Optional Parking Assist

Passive Safety Features:

Frontal airbags, side-impact airbags, side-curtain airbags, safety-belt pretensioners

💡 Technology Features

Infotainment System Options:

SYNC infotainment system (optional, with voice recognition and Bluetooth connectivity), Premium audio systems

Driver Assistance Features:

Optional rearview camera, parking sensors, cruise control

Cruise Control System:

Standard and potentially adaptive cruise control features detailed.

Connectivity Features:

Bluetooth for hands-free calling and audio streaming, USB ports

🔧 Maintenance

Oil Change Interval:

Typically 7,500 miles or 6 months, whichever comes first (refer to manual for specific engine/oil type)

Tire Rotation Interval:

Every 5,000 - 7,500 miles

Engine Air Filter Replacement:

Refer to manual for recommended mileage or visual inspection

Engine Oil Specification:

Synthetic 5W-20 motor oil meeting Ford specification WSS-M2C945-A or equivalent (refer to manual for exact type and capacity)

Coolant Specification:

Ford Ultimate Engine Coolant (UEC) - Yellow (60/40 mixture of antifreeze and distilled water)

Brake Fluid Specification:

DOT 3 or DOT 4 brake fluid (refer to manual for exact specification)

Hybrid Transaxle Fluid:

Specific fluid for e-CVT (refer to manual for Ford part number and specification)

Common Hybrid Issues:

Potential for high-voltage battery degradation over extended periods, issues with cooling systems, and occasional software glitches in hybrid control modules (manual will detail diagnostic procedures for these).

Common Powertrain Issues:

Wear on certain transmission components, occasional EVAP system leaks (manual provides diagnostic steps).

Common Electrical Issues:

Issues related to sensors, wiring harnesses, and control modules (manual provides diagnostic guidance).

📚 Vehicle History

Ford Brand Focus:

Ford's commitment to fuel efficiency and innovative powertrain technologies.

Fusion Lineage:

Part of the Ford Fusion mid-size sedan lineup, introduced to offer a more fuel-efficient and environmentally conscious option.

Hybrid Introduction:

The 2010-2013 models represent Ford's early offerings in the hybrid sedan segment, focusing on fuel efficiency and modern technology.

Manufacturing Location:

North America (e.g., Hermosillo, Mexico)