FUSION Ford HYBRID 2010-2013 Workshop Service Repair Manual
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🏷️ Basic Information Identification Make: Ford Model: Fusion Hybrid Model Generation: First Generation (CD391) Model Years Covered: 2010, 2011, 2012, 2013 Codes Platform Code: CD391 👋 Introduction Market Position Target Audience: Professional mechanics, dealership technicians, and experienced DIY car owners Competitive Analysis Value Proposition: Provides comprehensive, dealer-level repair information to save on professional service costs. Key Features Digital Accessibility: Instantly accessible on any device with PDF reader, no waiting for physical delivery. Searchability And Navigation: Well-structured content with bookmarks for efficient navigation and information retrieval. Accuracy And Detail: Detailed instructions and high-definition diagrams ensure accurate repairs. 📋 Manual Details Coverage Areas Manual Coverage Scope: Comprehensive Workshop Service and Repair Geographic Coverage: Primarily North American market specifications, but broadly applicable to global models with potential regional variations. Page Count Page Count: > 6800 Manual Type Manual Type: Workshop Service and Repair Manual / Owner's Manual Language Language: English Format Digital Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: 2.5L Duratec 25 I4, 3.0L Duratec 30 V6, 3.5L Duratec 35 V6, 2.5L Duratec 25 Hybrid (including Atkinson cycle operation) Hybrid System: High-voltage battery, electric motor-generators, power control unit, hybrid control module, regenerative braking system Transmission Systems: Manual Transmission, Aisin AW21 Automatic Transmission, 6F35 Automatic Transmission, e-CVT (Electronically Controlled Continuously Variable Transmission) Drivetrain: Driveline, Driveshaft, Axles, Differentials, Transfer Case System (if applicable to specific AWD variants), 4WD System (if applicable) Chassis And Suspension: Suspension System (front and rear), Wheels, Tires, Steering, Power Steering, Steering Column and Switches Brakes: Brake System, Parking Brakes, Hydraulic Brakes, Power Brake System, Anti-lock Brakes (ABS), Electronic Brake-force Distribution (EBD) Body And Interior: Body Panels System, Interior & Exterior Trim, Mirrors, Seats, Glass & Frame, Instrument Panel, Lock & Entry System, Wiper & Washer, Roof Panel, Body Repair, Body Mounting System Electrical And Electronics: Starting System, Charging System, Battery, Mounting & Cables, Ignition System, Emission Control, Evaporative Emission, Engine Control System, Instrument Cluster, Lighting System, Horn, Parking Aid, Entertainment System, Communication Network, Anti-theft System, Remote Convenience, Cruise Control System, Multifunction Electronics Climate Control: Climate Control System Safety And Restraint: Safety Belt System, Restraint System (Airbags) Emission Control Systems: Catalytic converter, oxygen sensors, evaporative emission control (EVAP) system Fuel Charging And Control: Fuel tank, fuel pump, fuel injectors, fuel pressure regulation Accessory Drive: Serpentine belt system, accessory pulleys, tensioners Intake Air System: Air filter, air intake manifold, mass air flow sensor Exhaust System: Exhaust manifold, catalytic converter, muffler, exhaust pipes Acceleration System: Throttle body, accelerator pedal position sensor Procedures Included Repair Procedures: Complete diagnostic procedures, component removal and installation, system repair and overhaul Maintenance Procedures: Periodic maintenance, fluid changes, filter replacements, inspections, lubrication Diagnostic Procedures: Troubleshooting guides, diagnostic trouble codes (DTCs), symptom-based diagnostics Specification Data: Torque specifications, electrical schematics, wiring diagrams, component data Electrical Schematics Coverage: Detailed wiring diagrams for all vehicle systems, including powertrain, body, chassis, and infotainment. Troubleshooting Charts: Extensive symptom-based troubleshooting charts to aid in diagnosing issues. Component Replacement Guides: Step-by-step guides for replacing major and minor components. Technical Depth Depth Of Coverage: Professional-level diagnostics and repair, suitable for both experienced technicians and DIY enthusiasts Diagnostic Tool Requirements: Information relevant to using Ford's diagnostic scan tools (e.g., IDS) for advanced diagnostics. Rebuild Procedures: Detailed procedures for engine and transmission rebuilds where applicable. 📊 Manual Specifications File Format File Type: Compressed ZIP archive containing PDF files Required Software: Adobe Acrobat Reader, WinZip/WinRAR (for extraction) Digital File Size: 188 MB Print Quality Printability: Printable pages Diagram Quality: High Definition Binding Type Binding Method: Not Applicable (Digital) Paper Type Paper Quality: Not Applicable (Digital) ⚙️ Engine Specifications Primary Engine Engine Options: 2.5L Duratec 25 I4, 3.0L Duratec 30 V6, 3.5L Duratec 35 V6, 2.5L Duratec 25 Hybrid Performance Engine Type Hybrid: Atkinson Cycle I4 with Electric Motor Assistance Fuel System Fuel Delivery Hybrid: Electronic Fuel Injection (EFI) Engine Control Engine Management System: Powertrain Control Module (PCM) / Hybrid Control Module (HCM) Engine Details Hybrid System Architecture: Ford's hybrid system integrates a gasoline engine with electric motor-generators for enhanced fuel economy and performance. 🔧 Transmission Standard Standard Transmission: e-CVT for Hybrid Models Optional Optional Transmissions: Manual Transmission, Aisin AW21 Automatic, 6F35 Automatic Features Hybrid Transmission Type: Electronically Controlled Continuously Variable Transmission (e-CVT) with integrated electric motor-generators Automatic Transmission Fluid: Specific Automatic Transmission Fluid (ATF) types required for AW21 and 6F35 (refer to manual for exact specifications) 📐 Dimensions Exterior Body Styles: 4-Door Sedan Weights Curb Weight Range: Approx. 3,600 - 4,000 lbs (depending on powertrain and options) 🛡️ Safety Features Ratings NHTSA Safety Ratings: Likely achieved high safety ratings (e.g., 5-star) during its model run; specific ratings to be confirmed within manual. Active Features Active Safety Systems: Anti-lock Braking System (ABS), Electronic Stability Control (ESC), Traction Control System (TCS), Optional Parking Assist Passive Features Passive Safety Features: Frontal airbags, side-impact airbags, side-curtain airbags, safety-belt pretensioners 💡 Technology Features Infotainment Infotainment...
SYNC infotainment system (optional, with voice recognition and Bluetooth connectivity), Premium audio systems
Driver Assistance
Driver Assistance Features:
Optional rearview camera, parking sensors, cruise control
Cruise Control System:
Standard and potentially adaptive cruise control features detailed.
Connectivity
Connectivity Features:
Bluetooth for hands-free calling and audio streaming, USB ports
🔧 Maintenance
Service Intervals
Oil Change Interval:
Typically 7,500 miles or 6 months, whichever comes first (refer to manual for specific engine/oil type)
Tire Rotation Interval:
Every 5,000 - 7,500 miles
Engine Air Filter Replacement:
Refer to manual for recommended mileage or visual inspection
Fluid Specifications
Engine Oil Specification:
Synthetic 5W-20 motor oil meeting Ford specification WSS-M2C945-A or equivalent (refer to manual for exact type and capacity)
Coolant Specification:
Ford Ultimate Engine Coolant (UEC) - Yellow (60/40 mixture of antifreeze and distilled water)
Brake Fluid Specification:
DOT 3 or DOT 4 brake fluid (refer to manual for exact specification)
Hybrid Transaxle Fluid:
Specific fluid for e-CVT (refer to manual for Ford part number and specification)
Known Issues
Common Hybrid Issues:
Potential for high-voltage battery degradation over extended periods, issues with cooling systems, and occasional software glitches in hybrid control modules (manual will detail diagnostic procedures for these).
Common Powertrain Issues:
Wear on certain transmission components, occasional EVAP system leaks (manual provides diagnostic steps).
Common Electrical Issues:
Issues related to sensors, wiring harnesses, and control modules (manual provides diagnostic guidance).
📚 Vehicle History
Brand Heritage
Ford Brand Focus:
Ford's commitment to fuel efficiency and innovative powertrain technologies.
Model Evolution
Fusion Lineage:
Part of the Ford Fusion mid-size sedan lineup, introduced to offer a more fuel-efficient and environmentally conscious option.
Hybrid Introduction:
The 2010-2013 models represent Ford's early offerings in the hybrid sedan segment, focusing on fuel efficiency and modern technology.
Production
Manufacturing Location:
North America (e.g., Hermosillo, Mexico)
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