Segment Positioning:
The Ford Fusion is a mid-size sedan known for its comfortable ride, refined interior, and a range of powertrain options, positioning it as a strong contender in its segment.
Key Competitors 2010-2012:
Toyota Camry, Honda Accord, Chevrolet Malibu, Nissan Altima, Mazda6
Manual Value Proposition:
Provides DIY enthusiasts and professional mechanics with the complete technical information required to diagnose, service, and repair all aspects of the Ford Fusion, saving significant time and money.
Vehicle Key Features During Period:
Stylish design, comfortable interior, available All-Wheel Drive (AWD) on some models, variety of engine choices including efficient 4-cylinders and V6 options.
Coverage Scope:
All Models, Engines, Trim Levels, and Transmission Types
Estimated Page Count:
Extensive (Thousands of pages)
Type:
Complete Workshop Service and Repair Manual
Delivery Format:
Downloadable Digital File (PDF)
Engine Systems:
Engine mechanical, engine performance, fuel system, lubrication system, cooling system, ignition system, emissions control, starting and charging system
Transmission Systems:
Manual transmission, automatic transmission (including specific models like 6F50/55), clutch, driveline, axles, CV joints
Chassis Systems:
Suspension (front and rear), steering system, brakes (hydraulic, ABS, traction control), wheels and tires
Electrical Systems:
Body electrical, lighting, power windows, locks, mirrors, seats, instrument cluster, diagnostic trouble codes (DTCs), wiring diagrams, fuse and relay locations
Body And Trim:
Body panels, doors, windows, exterior trim, interior trim, HVAC system, seats, airbags, restraints
Maintenance Procedures:
Routine inspections, oil changes, filter replacements, fluid checks and top-offs, tire rotation, brake inspections
Repair Procedures:
Engine disassembly and reassembly, transmission repair, brake component replacement, suspension component replacement, electrical component diagnosis and repair, body panel repair
Diagnostic Procedures:
Step-by-step troubleshooting guides for common and uncommon issues, using diagnostic tools, interpreting sensor data, diagnosing DTCs
Special Procedures:
Engine timing, torque specifications, procedures for specific component removal/installation (e.g., timing belt/chain, head gasket, transmission rebuild)
Depth:
Comprehensive from basic maintenance to complete engine and transmission overhauls, including detailed electrical schematics and diagnostic strategies.
Engine Options:
2.5L Duratec I4, 3.0L Duratec V6, 3.5L Duratec V6 (SHO model)
2.5L Duratec I4 Hp:
Approx. 175 hp @ 6000 rpm
2.5L Duratec I4 Torque:
Approx. 172 lb-ft @ 4500 rpm
3.0L Duratec V6 Hp:
Approx. 240 hp @ 6300 rpm
3.0L Duratec V6 Torque:
Approx. 222 lb-ft @ 4300 rpm
3.5L Duratec V6 Sho Hp:
Approx. 365 hp @ 5500 rpm
3.5L Duratec V6 Sho Torque:
Approx. 350 lb-ft @ 3500 rpm
Fuel Delivery:
Electronic Fuel Injection (EFI)
Recommended Fuel:
87 Octane Unleaded (89 recommended for 3.0L V6, 91 Octane recommended for 3.5L V6 SHO)
Common Engine Codes:
2.5L: ZNA, ZNB; 3.0L: ZV4; 3.5L SHO: ZV6
Standard Transmission:
6-speed automatic (e.g., 6F50)
Optional Transmission:
6-speed manual (available on some 2.5L models)
AWD Availability:
All-Wheel Drive (AWD) available on select models, typically with the 3.0L V6 engine.
Automatic Transmission Fluid Spec:
Mercon LV (e.g., Motorcraft XT-6-QSP or equivalent)
NHTSA Front Impact Driver:
5 Stars (2010-2012 models)
NHTSA Front Impact Passenger:
5 Stars (2010-2012 models)
IIHS Top Safety Pick:
Yes (2010-2012 models)
Standard Active Safety:
Anti-lock Braking System (ABS), Traction Control System (TCS), Electronic Stability Control (ESC - AdvanceTrac)
Standard Passive Safety:
Front airbags, front side airbags, side curtain airbags, front-seat active head restraints
Available Infotainment Systems:
Ford SYNC (voice-activated communications and entertainment system), optional navigation system, premium audio systems (e.g., Sony).
Available Driver Assistance:
Reverse sensing system, rearview camera (late in the model run or as accessory).
Connectivity Options:
Bluetooth connectivity for hands-free calling and music streaming (with SYNC).
Oil Change Interval:
Every 5,000-7,500 miles or 6 months, whichever comes first (depending on driving conditions and oil type used).
Air Filter Replacement Interval:
Every 15,000-30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement Interval:
Every 10,000-15,000 miles or annually.
Transmission Fluid Change Interval:
Every 30,000-100,000 miles, depending on transmission type and manufacturer recommendation (refer to manual for specific interval based on model/usage).
Engine Oil Specification:
SAE 5W-20 (API Certified)
Coolant Specification:
Ford Premium Concentrated Engine Coolant (Yellow) or equivalent meeting Ford specification WSS-M97B44-D
Brake Fluid Specification:
DOT 3
Common Complaints 2.5L Engine:
Occasional oil consumption, potential for PCV system issues.
Common Complaints V6 Engines:
Water pump leaks, occasional transmission shudder (especially early 6F50).
Common Complaints Chassis:
Early models may experience front suspension component wear (e.g., control arms, sway bar links), rear shock absorber leaks.
Common Complaints Electrical:
TPMS sensor issues, occasional power steering control module problems.
Ford Heritage:
Ford Motor Company, founded in 1903, is one of the world's largest automakers with a long history of innovation and popular vehicle models.
Fusion Introduction Year:
Introduced for the 2006 model year, replacing the Ford Five Hundred and Ford Taurus.
First Gen Facelift:
Received a significant refresh for the 2010 model year, including updated styling, interior, and powertrain options.
Assembly Locations:
Flat Rock, Michigan, USA; Hermosillo, Mexico
