🏷️ Basic Information

Make:

Ford

Model:

Fusion

Year:

2016

Generation Designation:

Second Generation (CD391)

Platform Code:

CD391

👋 Introduction

Vehicle Segment:

Mid-size Sedan (competing with Toyota Camry, Honda Accord, Chevrolet Malibu, Hyundai Sonata)

Target Audience:

Families, commuters, and individuals seeking a well-equipped, comfortable, and fuel-efficient sedan with available AWD and hybrid options.

Key Competitors 2016:

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

Available Powertrains:

Multiple engine options including efficient EcoBoost, powerful V6, and advanced hybrid systems.

Available Drivetrain:

Front-Wheel Drive (FWD) and All-Wheel Drive (AWD) options.

Technology Integration:

Advanced SYNC infotainment system, available driver-assist features.

Cost Savings Diy:

Enables owners to perform repairs and maintenance themselves, significantly reducing labor costs.

Ease Of Use:

Features easy-to-follow step-by-step instructions and pictures for all service and repair jobs.

📋 Manual Details

All Models Engines Trims Transmissions:

True

Estimated Page Count:

Comprehensive (exact count not specified, but implied to be extensive for 'Complete Workshop Service Repair Manual')

Manual Type:

Workshop Service Repair Manual

Language:

English

Delivery Format:

Downloadable Digital File (PDF)

📖 Manual Coverage

Engine Mechanical:

Yes (all variants including 1.5L EcoBoost, 2.0L EcoBoost, 2.5L Duratec, 2.7L EcoBoost V6, Hybrid powertrain components)

Engine Performance Control:

Yes (ECU, sensors, actuators, diagnostic procedures)

Transmission Automatic:

Yes (including DPS6 PowerShift, 6F35, Hybrid eCVT)

Transmission Manual:

Yes (where applicable to specific engine/drivetrain configurations)

Drivetrain AWD:

Yes (All-Wheel Drive system components and service)

Brakes System:

Yes (Hydraulic system, ABS, EPB - Electronic Parking Brake)

Suspension Steering:

Yes (Front/Rear suspension, steering rack, power steering system)

Body Structure Exterior:

Yes (Body panels, doors, hood, trunk, bumpers, glass, exterior trim)

Body Structure Interior:

Yes (Seats, trim panels, dashboard, headliner, HVAC system, interior controls)

Electrical System Chassis:

Yes (Lighting, power windows, locks, mirrors, wipers, horn)

Electrical System Powertrain:

Yes (Wiring diagrams for engine, transmission, hybrid components)

Instrumentation Driver Information:

Yes (Dashboard cluster, gauges, message center, SYNC system)

Climate Control HVAC:

Yes (AC system, heater, blower motor, controls)

Safety Restraint System Srs:

Yes (Airbags, seatbelts, related sensors and control modules)

Preventative Maintenance:

Yes (Oil changes, filter replacements, fluid checks/flushes, tune-ups)

Diagnostics Troubleshooting:

Yes (Step-by-step diagnostic procedures for common and complex issues, DTC interpretation)

Engine Repair Overhaul:

Yes (Engine assembly/disassembly, component replacement, timing, valve adjustments)

Transmission Service Repair:

Yes (Fluid changes, seal replacements, internal component repairs, clutch service)

Brake System Repair:

Yes (Brake pad/rotor replacement, caliper service, bleeding, ABS module diagnostics)

Suspension Steering Repair:

Yes (Component replacement - struts, shocks, ball joints, tie rods, power steering pump/rack)

Electrical Component Replacement:

Yes (Alternator, starter, battery, sensors, actuators, modules)

Body Panel Replacement Adjustment:

Yes (Fender, door, hood, trunk lid removal/installation and alignment)

HVAC System Repair:

Yes (Refrigerant service, component replacement - compressor, evaporator, condenser)

Srs System Diagnostics Repair:

Yes (Airbag module replacement, sensor calibration, related wiring)

Hybrid System Service:

Yes (High-voltage battery, electric motor, power split device, hybrid control module)

Depth Of Coverage:

Complete Workshop Service & Repair (A-Z), covering everything from routine maintenance to complex component overhauls and diagnostics.

Diagnostic Tools Required:

Implied to cover procedures requiring Ford's diagnostic scan tools (e.g., IDS) for advanced troubleshooting and module programming.

Torque Specifications:

Yes (Detailed torque values for all fasteners and assemblies)

Wiring Diagrams:

Yes (Comprehensive electrical schematics for all systems)

Special Tools:

Yes (Identification of specific tools required for certain procedures, with descriptions or part numbers where applicable)

📊 Manual Specifications

File Type:

PDF (Portable Document Format)

Searchability:

Searchable text content (if OCR processed appropriately)

Printability:

High quality, printable page by page or section by section.

Binding Type:

Not Applicable (Digital Download)

Paper Type:

Not Applicable (Digital Download)

Required Software:

Adobe Reader (or compatible PDF viewer)

Compatible Devices:

All PC & MAC Computers, tablets, smartphones, etc.

⚙️ Engine Specifications

Engine 1 Displacement:

1.5L EcoBoost I4

Engine 1 Horsepower:

178 hp @ 6000 rpm

Engine 1 Torque:

177 lb-ft @ 3000 rpm

Engine 2 Displacement:

2.0L EcoBoost I4

Engine 2 Horsepower:

240 hp @ 5500 rpm

Engine 2 Torque:

270 lb-ft @ 3000 rpm

Engine 3 Displacement:

2.5L Duratec I4

Engine 3 Horsepower:

175 hp @ 6000 rpm

Engine 3 Torque:

175 lb-ft @ 4500 rpm

Engine 4 Displacement:

2.7L EcoBoost V6

Engine 4 Horsepower:

325 hp @ 5000 rpm

Engine 4 Torque:

375 lb-ft @ 3500 rpm

Hybrid System Type:

Full Hybrid

Hybrid Engine Displacement:

2.0L Atkinson-cycle I4

Hybrid System Net Power:

188 hp (combined)

Fuel Induction Type:

Direct Injection (EcoBoost engines), Port Fuel Injection (Duratec, Hybrid)

Fuel Type:

Unleaded Gasoline (Regular unleaded acceptable for most, premium recommended for EcoBoost performance)

🔧 Transmission

Transmission Type Standard:

6-speed automatic (6F35) for 2.5L and 2.0L EcoBoost (FWD). 6-speed PowerShift (DPS6) for 1.5L EcoBoost.

Transmission Type Optional:

eCVT (Continuously Variable Transmission) for Hybrid model. 6-speed automatic (6F35) with AWD option for 2.0L EcoBoost.

Powershift Description:

Dual-clutch automatic transmission (DPS6) known for efficiency but also potential mechatronic issues.

AWD System:

Intelligent All-Wheel Drive system automatically distributes torque based on driving conditions.

📐 Dimensions

Length:

191.7 inches (4869 mm)

Width:

72.9 inches (1852 mm)

Height:

58.1 inches (1476 mm)

Wheelbase:

112.2 inches (2850 mm)

Trunk Volume:

Approximately 16.0 cubic feet (453 liters)

Curb Weight Range:

Approximately 3,400 - 3,900 lbs (1542 - 1769 kg) depending on powertrain and trim.

🛡️ Safety Features

NHTSA Overall Safety Rating:

Five-Star Overall Safety Rating (achieved by many configurations, consult NHTSA for specific trim details).

IIHS Top Safety Pick:

Typically awarded 'Top Safety Pick' or 'Top Safety Pick Plus' for good performance in crash tests.

ABS:

Standard Anti-lock Braking System (ABS)

Traction Control:

Standard Traction Control System (TCS)

Electronic Stability Control:

Standard Electronic Stability Control (ESC) / AdvanceTrac

Driver Assistance Available:

Adaptive Cruise Control, Blind Spot Information System (BLIS), Lane Keeping System, Cross-Traffic Alert, Parking Assist.

Airbags Front:

Dual front airbags

Airbags Side:

Front seat-mounted side airbags

Airbags Curtain:

Front and rear side-curtain airbags

Seatbelts:

Front and rear three-point seat belts, Belt Minder system.

💡 Technology Features

Infotainment System:

Ford SYNC system (SYNC, SYNC with MyFord Touch, or SYNC 3 depending on trim level and options).

Screen Size:

Available 4.2-inch or 8-inch touchscreen displays.

Smartphone Integration:

Available Apple CarPlay and Android Auto integration (with SYNC 3 and specific updates).

Adaptive Cruise Control:

Available Adaptive Cruise Control (ACC) that maintains a set distance from the vehicle ahead.

Blind Spot Monitoring:

Available Blind Spot Information System (BLIS) with Cross-Traffic Alert.

Lane Keeping:

Available Lane Keeping Assist and Lane Departure Warning systems.

Voice Control:

SYNC voice recognition for audio, phone, and climate control.

Navigation:

Available factory navigation system.

🔧 Maintenance

Oil Change Interval Gasoline:

Typically every 5,000-7,500 miles (8,000-12,000 km) or 6-12 months, depending on driving conditions and oil type (synthetic recommended).

Oil Change Interval Hybrid:

Typically every 7,500-10,000 miles (12,000-16,000 km) or 12 months, due to less frequent engine use.

Engine Oil Type:

SAE 5W-20 (meeting Ford specification WSS-M2C945-A or WSS-M2C960-A1 for EcoBoost engines). SAE 0W-20 for hybrid engine.

Coolant Type:

Motorcraft Yellow Prediluted Long Life Coolant (Ford specification WSS-M97B44-D3) or equivalent.

Transmission Fluid Type 6F35:

Mercon LV (Ford specification WSS-M2C938-A)

Transmission Fluid Type Powershift:

Motorcraft Dual Clutch Transmission Fluid (Ford specification WSS-M2C200-D2)

Hybrid Transmission Fluid:

Specific Ford hybrid transmission fluid (consult manual for exact specification)

Brake Fluid Type:

DOT 3 (Ford specification WSS-M6C65-A1) or DOT 4

Powershift Transmission Concerns:

Some early models with the DPS6 PowerShift transmission experienced issues with clutch shudder, harsh shifting, or transmission failure, often related to mechatronics unit or clutch pack wear.

Water Pump Leaks Ecoboost:

Some EcoBoost engines have experienced coolant leaks from the water pump or associated hoses.

Door Latch Issues:

Potential for door latch sticking or failure, requiring lubrication or replacement.

Sync System Glitches:

Infotainment system (SYNC) can sometimes exhibit glitches, requiring software updates or resets.

📚 Vehicle History

Ford Legacy:

Ford Motor Company, a global automotive manufacturer with over a century of innovation and production, known for popular models like the Model T, F-Series trucks, and Mustang.

Fusion Introduction:

The Ford Fusion was first introduced for the 2006 model year, replacing the Ford Mondeo in North America. The 2013 model year saw a significant redesign, ushering in the second generation (CD391) on which this manual is based.

Manufacturing Locations:

Primarily produced at the Flat Rock Assembly Plant in Flat Rock, Michigan, USA.

Production Years Second Gen:

2013-2020

🏆 Awards & Recognition

IIHS Awards:

Regularly recognized by the Insurance Institute for Highway Safety (IIHS) for its safety performance.

Consumer Reports Ratings:

Often received above-average or average ratings from organizations like Consumer Reports for various aspects including comfort and fuel economy.