Ford FUSION 2006 Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Fusion Year: 2006 Codes Chassis Code: First Generation (Fusion) 👋 Introduction Market Position Segment: Mid-size sedan Target Audience: Families, commuters, individuals seeking a...

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Description

🏷️ Basic Information

Identification

Make:

Model:

Fusion

Year:

Codes

Chassis Code:

First Generation (Fusion)

👋 Introduction

Market Position

Segment:

Mid-size sedan

Target Audience:

Families, commuters, individuals seeking a reliable and practical sedan.

Competitive Analysis

Key Competitors:

Toyota Camry, Honda Accord, Nissan Altima, Chevrolet Malibu, Chrysler Sebring.

Key Features

Design Philosophy:

European-inspired styling and driving dynamics, offering a comfortable and engaging driving experience.

Powertrain Options:

Available with efficient 4-cylinder and capable V6 engines.

Interior Comfort:

Spacious cabin with quality materials and ergonomic design.

📋 Manual Details

Coverage Areas

Manual Type:

Service and Repair Manual

Language:

English

Format:

Delivery Method:

Instant Download

Printable:

Full Printable

Zoom Functionality:

Zoom IN/OUT Supported

Software Requirements:

Adobe PDF Reader, WinZip

Operating System Compatibility:

All Versions of Windows & Mac

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine assembly, disassembly, troubleshooting, diagnostics, performance tuning, emission controls.

Engine Electrical:

Ignition system, starting system, charging system, fuel injection system, engine control module (ECM) diagnosis.

Transmission Automatic:

Service and repair procedures for automatic transmissions, including fluid changes, torque converter service, valve body diagnosis, and complete rebuild instructions.

Transmission Manual:

Service and repair procedures for manual transmissions, including clutch service, gearbox disassembly, and component replacement.

Drivetrain:

Front-wheel drive (FWD) axle shafts, CV joints, differential service, rear axle components (if applicable).

Brakes:

Disc brake systems (front and rear), brake fluid, anti-lock braking system (ABS) components, hydraulic lines, master cylinder, calipers, rotors, pads, parking brake.

Suspension:

Front suspension (struts, control arms, ball joints, bushings), rear suspension (shocks, springs, control arms), alignment specifications, wheel bearings.

Steering:

Power steering system (pump, reservoir, lines, rack and pinion), steering column, tie rods, steering linkage.

Exhaust System:

Exhaust manifolds, catalytic converter, mufflers, pipes, oxygen sensors, emission control devices.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel lines, evaporative emission control (EVAP) system.

Cooling System:

Radiator, coolant hoses, water pump, thermostat, cooling fan, heater core, pressure cap.

Electrical System:

Wiring diagrams, fuses, relays, lighting system (headlights, taillights, interior lights), battery, horn, power windows, locks, mirrors.

HVAC System:

Air conditioning (compressor, refrigerant, condenser, evaporator), heating system, climate control unit, blower motor.

Body And Interior:

Body panel removal and installation, door mechanisms, interior trim, seats, dashboard, sunroof, glass replacement.

Chassis Electrical:

Body control module (BCM), instrument cluster, trailer wiring, diagnostic connector (OBD-II).

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, fluid checks and top-offs, tire rotation, battery maintenance.

Troubleshooting:

Diagnostic charts, symptom-based troubleshooting for common issues, electrical system diagnosis.

Repair Procedures:

Step-by-step instructions for component removal, repair, and reinstallation for all covered systems.

Diagnostic Testing:

Procedures for using diagnostic tools and equipment, interpreting scan tool data, performing electrical tests.

Specifications And Tolerances:

Torque specifications for fasteners, fluid capacities, alignment angles, engine build clearances, electrical component resistance values.

Exploded Views:

Detailed exploded views and diagrams to illustrate component relationships and assembly order.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for all vehicle systems.

Technical Depth

Depth:

Covers a wide range from basic DIY maintenance to complex mechanical and electrical repairs, suitable for both novice and experienced technicians.

📊 Manual Specifications

File Format

Format:

Quality:

High resolution for clear text and diagrams

Print Quality

Printability:

Full printable pages, allowing for physical copies

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Code 1:

Duratec 2.3L I4

Displacement 1:

2.3 Liters (2295 cc)

Horsepower 1:

160 hp @ 6250 rpm

Torque 1:

152 lb-ft @ 4400 rpm

Fuel System 1:

Electronic Fuel Injection (EFI)

Fuel Type 1:

Unleaded Gasoline

Optional Engine

Engine Code 2:

Duratec 3.0L V6

Displacement 2:

3.0 Liters (2967 cc)

Horsepower 2:

221 hp @ 6250 rpm

Torque 2:

200 lb-ft @ 4300 rpm

Fuel System 2:

Electronic Fuel Injection (EFI)

Fuel Type 2:

Unleaded Gasoline

🔧 Transmission

Standard

Transmission Type Standard:

5-speed Manual Transmission (MTX-75)

Optional

Transmission Type Optional:

6-speed Automatic Transmission (AX4N or similar)

Features

Transmission Fluid Spec Auto:

Mercon V (Check manual for specific fill capacity)

Transmission Fluid Spec Manual:

DOT 3 Brake Fluid (for clutch hydraulic system), Manual Transmission Fluid (e.g., Mercon GL-4, specific viscosity varies)

📐 Dimensions

Exterior

Length:

188.2 inches

Width:

72.2 inches

Height:

57.0 inches

Wheelbase:

107.4 inches

Weights

Curb Weight Approx I4:

3240 lbs

Curb Weight Approx V6:

3400 lbs

🛡️ Safety Features

Ratings

NHTSA Front Impact Driver:

Good (4-star)

NHTSA Front Impact Passenger:

Good (4-star)

NHTSA Side Impact Front Seat:

Good (5-star)

NHTSA Side Impact Rear Seat:

Good (5-star)

IIHS Moderate Overlap Frontal:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Available Traction Control System (TCS)

Passive Features

Airbags Front:

Standard front driver and passenger airbags

Airbags Side:

Available front side-impact airbags and full-length side curtain airbags

Seatbelts:

3-point height-adjustable front seat belts with pretensioners, 3-point rear seat belts.

💡 Technology Features

Infotainment

Audio System:

Available AM/FM stereo with CD player, optional SiriusXM satellite radio, and premium audio system upgrades.

Display:

Standard instrument cluster with analog gauges, optional in-dash information display.

Driver Assistance

Cruise Control:

Standard cruise control

Parking Assist:

Rear parking assist sensors available on some trims.

Connectivity

Aux Input:

Available auxiliary audio input jack for portable music players.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 to 7,500 miles or 6 months, whichever comes first (dependent on oil type and driving conditions).

Engine Air Filter:

Inspect every 15,000 miles, replace as needed or every 30,000 miles.

Cabin Air Filter:

Replace annually or every 15,000 miles, or more frequently in dusty conditions.

Spark Plugs I4:

Replace every 100,000 miles (typically iridium-tipped plugs).

Spark Plugs V6:

Replace every 100,000 miles (typically iridium-tipped plugs).

Fluid Specifications

Engine Oil Spec I4 V6:

SAE 5W-20 (API Service SG or higher)

Coolant Spec:

Ford Premium Engine Coolant (Orange, Premium Long Life)

Brake Fluid Spec:

DOT 3

Known Issues

Common Problem 1:

Powertrain Control Module (PCM) issues leading to rough idling or stalling.

Common Problem 2:

Transmission solenoid issues causing shifting problems in automatic transmissions.

Common Problem 3:

Evaporative Emission (EVAP) system leaks, often related to charcoal canister or purge valves.

Common Problem 4:

Front suspension component wear, such as control arm bushings and ball joints.

Common Problem 5:

Interior electrical gremlins, including window regulators and door lock actuators.

📚 Vehicle History

Brand Heritage

Ford Sedan Legacy:

Ford has a long history of producing popular sedans, building on models like the Taurus and Contour.

Model Evolution

First Generation Launch:

The Ford Fusion was introduced for the 2006 model year, replacing the Ford Contour and Mercury Mystique.

Platform:

Built on Ford's CD3 platform, shared with the Mazda6 and Mercury Milan.

Production

Manufacturing Location:

Flat Rock, Michigan, USA

Model Years Covered By Manual:

Exclusively covers the 2006 model year.

🏆 Awards & Recognition

Recognitions

Award 1:

Insurance Institute for Highway Safety (IIHS) Top Safety Pick (for earlier models, indicating strong safety performance).

Award 2:

Kelley Blue Book's Best Resale Value Award (often cited for the Fusion model range).