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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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🏷️ 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 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:
PDF
Searchable:
Yes
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
ABS:
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.