🏷️ Basic Information

Make:

Ford

Model:

Fusion

Year Range:

2006-2009

Vehicle Segment:

Mid-size Sedan

Paint Code Location Description:

Information provided on locating paint codes.

Clear Coat Identification:

Details on clear coat identification included.

Information Labels Description:

Guidance on locating and understanding information labels.

👋 Introduction

Target Audience:

DIY mechanics, independent repair shops, and Ford Fusion owners seeking to perform their own maintenance and repairs.

Value Proposition:

Provides essential part identification and cost information (parts price and labor) for a specific range of Ford Fusion models, bridging the gap between official factory service manuals and general repair guides.

Primary Benefit:

Empowers users to accurately identify and order the correct replacement parts, reducing errors and saving time.

Additional Benefit:

The inclusion of labor information provides a baseline for estimating repair costs and DIY feasibility.

📋 Manual Details

Overall Coverage:

Comprehensive parts catalog for DIY repairs.

Body Exterior:

Front bumper, grille, hood, front fender, rocker/pillars/floor, quarter panel, rear body, rear bumper, liftgate, front door, rear door, roof, sunroof, quarter glass.

Body Interior:

Center console, front seat, rear seat, instrument panel, windshield, cowl & dash.

Engine Cooling Exhaust:

Cooling system, A/C refrigerant capacities, A/C/Heater/Ventilation, engine under cover, air cleaner, exhaust, emission system.

Suspension Steering Brakes:

Front suspension, front drive axle, front steering linkage/gear, steering pump, steering wheel/column, ABS/brakes, rear suspension, rear drive axle.

Electrical Safety:

Electrical system, front lamps, rear lamps, air bag system, seat belts, cruise control system.

Special Instructions:

Special cautions, front impact kit.

Estimated Page Count:

Not specified, but extensive coverage implies a substantial document.

Type:

Parts Catalog / Repair Information

Purpose:

Facilitate DIY repairs by identifying correct spare parts and their numbers.

Language:

English

Primary Format:

Searchable PDF

Features:

Linked bookmarks, easy to save, use, zoom, and print.

📖 Manual Coverage

Powertrain Excluded Components:

Internal engine components (e.g., pistons, crankshafts, valves) are not covered; focus is on external and related systems.

Body Hardware:

Extensive coverage of body panels, trim, lighting, glass, and related hardware.

Chassis Suspension:

Detailed listing of suspension components, steering linkage, and axle parts.

Climate Control:

Covers HVAC components and essential refrigerant capacity information.

Braking Safety Systems:

Includes ABS components, brake system parts, and airbag system components.

Part Identification:

Primary function is to locate and verify part numbers using illustrations.

Labor Information:

Includes labor information, likely for estimation of repair times, crucial for DIYers.

Component Illustration:

Detailed component illustrations are a core feature for visual part identification.

Paint Code Retrieval:

Guidance on finding the vehicle's paint code for touch-up or replacement.

Depth:

Focuses on parts identification and labor estimation rather than detailed repair procedures or diagnostics.

Diagnostic Scope:

Does not provide diagnostic flowcharts or troubleshooting guides for system failures.

Repair Scope:

Facilitates repairs by ensuring the correct parts are sourced; does not detail the 'how-to' of the repair itself.

📊 Manual Specifications

Format:

Portable Document Format (PDF)

Searchability:

Searchable text, allowing for quick keyword-based information retrieval.

Printability:

Designed to be printable, allowing users to create physical copies of sections or the entire document.

Binding:

N/A (Digital PDF)

Paper Type:

N/A (Digital PDF)

⚙️ Engine Specifications

Available Engines 2006-2009:

While the manual focuses on parts, the Fusion for these years typically offered 2.3L I4, 2.5L I4 (later years), and 3.0L V6 Duratec engines. Specific parts for these would be listed.

Engine Power Range:

Approx. 160 hp (2.3L) to 263 hp (3.0L V6 Sport trim).

Engine Torque Range:

Approx. 150 lb-ft (2.3L) to 249 lb-ft (3.0L V6 Sport trim).

Fuel Delivery:

Electronic Fuel Injection (EFI) is standard across all engine variants.

A C Refrigerant Capacity:

Specific refrigerant capacity (likely R-134a) is detailed in the manual.

🔧 Transmission

Transmission Options:

The Fusion offered both 5-speed manual and 6-speed automatic transmissions, depending on engine and trim.

Optional Transmission:

All-Wheel Drive (AWD) was available on select models, typically paired with automatic transmissions.

Transmission Components:

Parts related to transmission mounts, and potentially external components, would be covered.

📐 Dimensions

Length Approx:

Around 191 inches (4851 mm)

Width Approx:

Around 72 inches (1829 mm)

Height Approx:

Around 58 inches (1473 mm)

Curb Weight Range:

Approximately 3,300 - 3,600 lbs (1497 - 1633 kg), varying by engine and drivetrain.

Trunk Volume Approx:

Around 15.2 cubic feet (430 liters)

🛡️ Safety Features

NHTSA Front Crash Rating:

Generally received 5-star ratings for driver and passenger front crash protection in NHTSA tests.

IIHS Front Overlap Rating:

Tested by IIHS, performance varied slightly by year but generally good.

ABS:

Standard Anti-lock Braking System (ABS) across most trims, with components detailed in the catalog.

Traction Control:

Traction control system (TCS) was available, particularly on higher trims or with certain powertrains.

Airbags:

Standard front airbags, with side-curtain airbags and front-seat side airbags often available or standard on higher trims. The manual covers these system components.

Seat Belts:

Includes information on seat belt components, a critical safety feature.

💡 Technology Features

Available Systems:

Base models had a standard audio system; higher trims featured optional Audiophile sound systems, and the SYNC infotainment system was introduced during this generation, offering Bluetooth connectivity and voice commands.

Cruise Control:

Cruise control was a widely available feature, with components covered in the manual.

Sync Availability:

Ford SYNC system became available, enhancing hands-free calling and music control.

🔧 Maintenance

Oil Change Interval:

Typically every 5,000 miles or 6 months for conventional oil, or 7,500-10,000 miles/6-12 months for synthetic oil, subject to driving conditions.

Major Service Points:

Spark plug replacement (around 100,000 miles), coolant flush, transmission fluid change are key points not detailed here but supported by parts lookup.

Engine Oil Specification:

Recommended viscosity typically SAE 5W-20 (check owner's manual for specific engine). Synthetic or synthetic blend often recommended.

Coolant Specification:

Ford Premium Engine Coolant (yellow) or equivalent, typically a 50/50 mix with distilled water.

Transmission Fluid Specification:

Mercon V for automatic transmissions, manual transmission fluid (MTF) for manual gearboxes.

Common Wear Items:

Brake pads/rotors, suspension components (ball joints, tie rods), engine mounts, and catalytic converters can be common wear items.

Potential Reliability Concerns:

Some earlier models experienced transmission issues, power steering problems, and occasional electrical gremlins. The parts catalog aids in replacing these components.

📚 Vehicle History

Ford Sedan Legacy:

The Ford Fusion succeeded models like the Ford Contour and Taurus, aiming to capture a significant share of the mid-size sedan market.

First Generation:

The 2006-2009 models represent the first generation of the Ford Fusion, introduced as a 2006 model year vehicle.

Platform:

Based on the Mazda GG platform (shared with Mazda6).

Manufacturing Location:

Primarily manufactured at the Ford Michigan Assembly Plant in Wayne, Michigan, USA.

Production Years:

2005 (for MY2006) through 2009 for this specific generation.

🏆 Awards & Recognition

Car And Driver 10Best:

The Ford Fusion was recognized on Car and Driver's 10Best lists in 2007 and 2008, highlighting its blend of refinement, handling, and value.

Consumer Reports Reliability:

Reliability ratings varied by model year and specific components, with some years performing better than others. This manual helps address parts for any required repairs.

Safety Certifications:

Meets all federal motor vehicle safety standards (FMVSS) for its production years.