Market Position:
The Ford Fusion, particularly in its Hybrid and Energi variants, occupied a significant segment of the mid-size sedan market, appealing to buyers seeking fuel efficiency and modern features. This manual caters to owners and technicians looking to maintain and repair these sophisticated vehicles.
Competitive Analysis:
The Fusion competed with models like the Toyota Camry Hybrid, Honda Accord Hybrid, and Chevrolet Malibu Hybrid. Its strengths included stylish design, refined driving dynamics, and advanced technology, making a comprehensive service manual essential for its upkeep.
Key Features:
The 2013-2018 Ford Fusion generation introduced more aerodynamic styling, improved interior quality, and advanced powertrain options, including the highly efficient Hybrid and plug-in Energi models. This manual reflects the complexity of these advancements.
Engine Systems:
Engine mechanical, lubrication, cooling, fuel, ignition, emissions control, engine management, turbocharging (if applicable), hybrid powertrain components (high-voltage battery, electric motor, power control module), Energi plug-in hybrid system.
Transmission Systems:
Automatic transmission (CVT for Hybrid), Hybrid/EV transaxle, powertrain control module (PCM), transmission fluid specifications, troubleshooting.
Brake Systems:
Hydraulic system, ABS, traction control, stability control, brake fluid specifications, disc/drum components, parking brake, regenerative braking system for hybrids.
Suspension Steering Systems:
Front and rear suspension, steering column, power steering, steering gear, wheel alignment specifications, hub assemblies, tires, wheels.
Electrical Systems:
12V battery, charging system, starter motor, lighting systems, instrumentation, power accessories, body control module (BCM), gateway module, hybrid high-voltage electrical systems, charging system for Energi models, wiring diagrams.
HVAC Systems:
Air conditioning, heating, climate control, refrigerant, system diagnostics, cabin air filter.
Body Exterior Interior:
Body panel repair, doors, windows, glass, mirrors, sunroof, interior trim, seating, safety restraints (airbags, seatbelts).
Diagnostic Systems:
OBD-II diagnostics, diagnostic trouble codes (DTCs), scan tool usage, system-specific diagnostic procedures.
Maintenance Procedures:
Oil changes, fluid checks and changes (coolant, brake fluid, transmission fluid, power steering fluid), filter replacements (oil, air, cabin), spark plug replacement, belt inspection/replacement, battery maintenance, tire rotation and inflation.
Repair Procedures:
Engine component replacement (e.g., head gasket, water pump, alternator), transmission repair/replacement, brake component replacement (pads, rotors, calipers), suspension component replacement (shocks, struts, control arms), steering system repair, electrical component diagnosis and replacement, HVAC system repair, body panel repair and refinishing.
Troubleshooting Procedures:
Step-by-step diagnostic flowcharts for common and uncommon issues, symptom-based troubleshooting guides, electrical diagnostic procedures using wiring diagrams.
Hybrid Specific Procedures:
High-voltage battery system service (cautionary procedures), electric motor service, power split device service, charging system service for Energi models, hybrid control module diagnostics.
Technical Specifications:
Torque specifications for all fasteners, engine bore/stroke, compression ratios, valve clearances (if applicable), fluid capacities, tire pressure recommendations, wiring diagrams, component locations, diagnostic trouble code (DTC) definitions and procedures.
Technical Depth:
Comprehensive (from basic maintenance to advanced diagnostics and component rebuilds).
Fusion Hybrid Engine Type:
Atkinson-cycle 2.5L 4-cylinder (Hybrid) combined with an electric motor.
Fusion Energi Engine Type:
Atkinson-cycle 2.0L 4-cylinder (Plug-in Hybrid) combined with a higher-capacity electric motor and larger battery pack.
Fusion Hybrid Total System Hp Approx:
188 hp
Fusion Energi Total System Hp Approx:
188 hp
Fusion Hybrid Fuel System:
Electronic fuel injection (EFI) with Atkinson cycle for efficiency.
Fusion Energi Fuel System:
Electronic fuel injection (EFI) with Atkinson cycle for efficiency, plug-in charging capability.
Fusion Gasoline Engine Options:
While this manual focuses on hybrids/Energi, the platform also utilized 1.5L, 1.6L EcoBoost, and 2.0L EcoBoost gasoline engines for non-hybrid models.
NHTSA Overall Safety Rating:
Generally rated 5-Star Overall (specific year/configuration dependent).
IIHS Top Safety Pick:
Likely achieved 'Top Safety Pick' or 'Top Safety Pick+' in various years.
Active Safety Features:
Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control System (TCS), available Blind Spot Information System (BLIS), Cross-Traffic Alert, Lane Departure Warning, Lane Keeping Assist, Adaptive Cruise Control.
Passive Safety Features:
Multiple airbags (front, side, curtain), front seatbelt pretensioners, advanced seatbelt systems, body structure designed for impact absorption.
Infotainment System:
SYNC system (SYNC, SYNC with MyFord Touch, SYNC 3), touchscreen interface, Bluetooth connectivity, voice control, navigation (optional), SiriusXM Satellite Radio.
Driver Assistance Features:
Includes features like adaptive cruise control, lane-keeping assist, blind-spot monitoring, cross-traffic alert, parking assist.
Connectivity Features:
USB ports, Bluetooth streaming, available Wi-Fi hotspot (depending on trim and options).
Hybrid Technology Features:
Regenerative braking, electric-only driving capability, automatic engine start-stop, intelligent battery management.
Oil Change Interval:
Typically 7,500 to 10,000 miles or 6-12 months with synthetic oil, depending on driving conditions. Always follow manual recommendations.
Tire Rotation Interval:
Every 5,000 - 7,500 miles.
Cabin Air Filter Replacement:
Every 15,000 - 20,000 miles or annually.
Coolant Flush Interval:
Consult manual, typically around 100,000 miles for the first change, then every 50,000-60,000 miles.
Engine Oil Spec:
SAE 0W-20, API SN/SP certified synthetic blend or full synthetic. Verify specific engine requirement.
Coolant Spec:
Ford Gold Coolant (G12) or equivalent; a 50/50 mix of coolant and deionized water.
Brake Fluid Spec:
DOT 3 or DOT 4. Consult manual for precise specification.
Known Issues Hybrid Battery:
While generally reliable, high-voltage batteries can degrade over time, potentially impacting efficiency and performance. Repair/replacement is costly and requires specialized knowledge.
Known Issues Powertrain Control:
Occasional issues with powertrain control modules or sensors can lead to check engine lights or performance anomalies, especially related to hybrid system integration.
Known Issues Evap System:
Evaporative Emission Control System (EVAP) leaks can cause evaporative emissions codes.
Brand Heritage:
Ford has a long history of producing reliable and innovative vehicles, with the Fusion representing its modern approach to global platforms and fuel-efficient powertrains.
Model Evolution 2013 Refresh:
The 2013 model year marked a significant redesign for the Fusion, adopting a sleeker, Aston Martin-like grille and a more sophisticated interior. The Hybrid and Energi models were key components of this new generation, emphasizing Ford's commitment to electrification.
Model Evolution Mid Cycle Updates:
Minor updates in subsequent years often included infotainment system enhancements, new driver-assist technologies, and minor styling tweaks. The core powertrain and chassis remained largely consistent.
Production Location:
Built at the Ford Flat Rock Assembly Plant in Flat Rock, Michigan, USA.
