Ford Fusion 2006 to 2009 Factory Service Repair Manual

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🏷️ Basic Information Identification Make: Ford Model: Fusion Generation: First Generation Codes Platform: CD3 Platform 👋 Introduction Market Position Segment: Mid-size Sedan Target Audience: Families, commuters, individuals seeking a reliable and comfortable sedan. Competitive Analysis Key Competitors: Toyota Camry, Honda Accord, Chevrolet Malibu, Nissan Altima. Key Features Design Philosophy: American interpretation of European styling, offering a sportier alternative to some competitors. Powertrain Options: Available with efficient 4-cylinder and powerful V6 engines, with optional AWD for enhanced traction. Interior Comfort: Spacious interior, comfortable seating, and a generally well-appointed cabin for its class. 📋 Manual Details Coverage Areas Model Years Covered: 2006, 2007, 2008, 2009 Drivetrain Variants Covered: 2WD (Front-Wheel Drive), AWD (All-Wheel Drive) Page Count Estimated Page Count: Approx. 3000+ pages (typical for comprehensive factory service manuals) Manual Type Manual Type: Factory Service Repair Manual (FSM) Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, component inspection, timing, lubrication, cooling system, exhaust system, emissions control systems. Engine Performance: Fuel injection, ignition system, diagnostic trouble codes (DTCs), powertrain control module (PCM) operation. Transmission Manual: Manual transaxle service, clutch system, shift linkage, fluid specifications. Transmission Automatic: Automatic transaxle service (e.g., AX4N/4F50N for V6), hydraulic control, electronic controls, torque converter, fluid specifications. Drivetrain AWD: All-Wheel Drive (AWD) system components, transfer case, propeller shaft, rear differential, CV joints, hubs. Suspension System: Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, wheel bearings, alignment specifications. Steering System: Power steering system (hydraulic or electric), steering column, steering rack and pinion, tie rods, alignment. Brake System: Front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, rotors, pads, lines, hydraulic system, bleeding procedures. Electrical System Basic: Battery, charging system (alternator, starter motor), lighting system, fuses, relays, wiring diagrams. Electrical System Advanced: Body control module (BCM), Powertrain Control Module (PCM), infotainment system, climate control module, power windows, locks, mirrors, instrument cluster. HVAC System: Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, blower motor, climate control panel. Body Exterior: Body panels, doors, hood, trunk, bumpers, glass, trim, weatherstripping, body repairs. Body Interior: Interior trim panels, seats, dashboard, airbags, seat belts, sound deadening. Safety Restraints: Airbag system diagnosis and replacement, seat belt pretensioners, SRS module. Procedures Included Scheduled Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake service. Troubleshooting: Diagnostic procedures for various systems, symptom-based troubleshooting charts, diagnostic trouble code (DTC) interpretation. Repair Procedures: Step-by-step instructions for component removal, replacement, and reinstallation for all major systems. Diagnostic Procedures: Using diagnostic tools (like OBD-II scanners), circuit testing, component testing, parameter identification. Wiring Diagrams: Detailed electrical schematics for all vehicle systems, including connector pinouts and wire colors. Specifications And Data: Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic data. Technical Depth Depth Of Coverage: Comprehensive coverage from basic maintenance to major component overhaul and advanced diagnostics. Repair Complexity: Suitable for DIY mechanics and professional technicians alike, detailing intricate procedures. 📊 Manual Specifications File Format File Format: PDF (Portable Document Format) Print Quality Printability: High-resolution PDF optimized for clear printing, allowing for easy zooming and readability. Searchability: Typically includes searchable text layers for quick information retrieval. Binding Type Binding Type: Not Applicable (Digital PDF) Paper Type Paper Type: Not Applicable (Digital PDF) Compatibility Operating System Compatibility: Windows and macOS ⚙️ Engine Specifications Primary Engine Engine Option 1 2.3L: 2.3L Duratec I4 (Mazda L3-VE) Engine Option 1 Specs: Inline-4, DOHC, 16 valves, 2.3 liters. Horsepower: ~160 hp @ 6200 rpm. Torque: ~150 lb-ft @ 4000 rpm. Engine Option 2 3.0L: 3.0L Duratec 30 V6 (Ford 'Sable' V6) Engine Option 2 Specs: V6, DOHC, 24 valves, 3.0 liters. Horsepower: ~200-215 hp @ 6000 rpm. Torque: ~200-205 lb-ft @ 4000 rpm. Performance Engine Design: Aluminum block and heads, chain-driven camshafts. Engine Cooling: Pressurized liquid cooling system with thermostatically controlled fan. Fuel System Fuel Delivery: Electronic Fuel Injection (EFI) with sequential port injection. Fuel Type: Unleaded gasoline, minimum 87 octane (87 AKI). Emission Control: Catalytic converter, oxygen sensors, evaporative emissions control (EVAP) system. 🔧 Transmission Standard Transmission Option 1 4-Cyl: 5-speed Manual Transmission (MTX-75) for 2.3L models. Optional Transmission Option 2 4-Cyl AWD: 5-speed Automatic Transaxle (4F50N) for 2.3L AWD models. Transmission Option 3 V6: 5-speed Automatic Transaxle (AX4N/4F50N) for 3.0L V6 models (available with 2WD and AWD). Features Automatic Transmission Features: SelectShift capability (manual shifting modes) on some automatic transmissions. AWD System Type: Active All-Wheel Drive system, typically electronically controlled viscous coupling and rear differential. Fluid Specifications Manual Transmission Fluid Spec: Mercon V or equivalent manual transmission fluid. Automatic Transmission Fluid Spec: Mercon V or equivalent automatic transmission fluid (e.g., Motorcraft XT-5QSP). 📐 Dimensions Exterior Wheelbase: 107.4 inches (2728 mm) Length: 191.1 inches (4854 mm) Width: 72.4 inches (1839 mm) Height: 57.7 inches (1466 mm) Wheel Bolt Pattern: 5x114.3 mm...

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Type: Car

Sku: 264255

Collections: ALL Ford

Availability: In stock

Tags: 2006 2007 2008 2009 Car Cars Ford Fusion

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Description

🏷️ Basic Information

Identification

Make:

Model:

Fusion

Generation:

First Generation

Codes

Platform:

CD3 Platform

👋 Introduction

Market Position

Segment:

Mid-size Sedan

Target Audience:

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

Competitive Analysis

Key Competitors:

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

Key Features

Design Philosophy:

American interpretation of European styling, offering a sportier alternative to some competitors.

Powertrain Options:

Available with efficient 4-cylinder and powerful V6 engines, with optional AWD for enhanced traction.

Interior Comfort:

Spacious interior, comfortable seating, and a generally well-appointed cabin for its class.

📋 Manual Details

Coverage Areas

Model Years Covered:

2006, 2007, 2008, 2009

Drivetrain Variants Covered:

2WD (Front-Wheel Drive), AWD (All-Wheel Drive)

Page Count

Estimated Page Count:

Approx. 3000+ pages (typical for comprehensive factory service manuals)

Manual Type

Manual Type:

Factory Service Repair Manual (FSM)

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, component inspection, timing, lubrication, cooling system, exhaust system, emissions control systems.

Engine Performance:

Fuel injection, ignition system, diagnostic trouble codes (DTCs), powertrain control module (PCM) operation.

Transmission Manual:

Manual transaxle service, clutch system, shift linkage, fluid specifications.

Transmission Automatic:

Automatic transaxle service (e.g., AX4N/4F50N for V6), hydraulic control, electronic controls, torque converter, fluid specifications.

Drivetrain AWD:

All-Wheel Drive (AWD) system components, transfer case, propeller shaft, rear differential, CV joints, hubs.

Suspension System:

Front suspension (MacPherson strut), rear suspension (multi-link), shock absorbers, springs, control arms, wheel bearings, alignment specifications.

Steering System:

Power steering system (hydraulic or electric), steering column, steering rack and pinion, tie rods, alignment.

Brake System:

Front and rear disc brakes, ABS (Anti-lock Braking System), EBD (Electronic Brakeforce Distribution), brake calipers, rotors, pads, lines, hydraulic system, bleeding procedures.

Electrical System Basic:

Battery, charging system (alternator, starter motor), lighting system, fuses, relays, wiring diagrams.

Electrical System Advanced:

Body control module (BCM), Powertrain Control Module (PCM), infotainment system, climate control module, power windows, locks, mirrors, instrument cluster.

HVAC System:

Heating, Ventilation, and Air Conditioning (HVAC) system, refrigerant, compressor, condenser, evaporator, blower motor, climate control panel.

Body Exterior:

Body panels, doors, hood, trunk, bumpers, glass, trim, weatherstripping, body repairs.

Body Interior:

Interior trim panels, seats, dashboard, airbags, seat belts, sound deadening.

Safety Restraints:

Airbag system diagnosis and replacement, seat belt pretensioners, SRS module.

Procedures Included

Scheduled Maintenance:

Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt inspection and replacement, brake service.

Troubleshooting:

Diagnostic procedures for various systems, symptom-based troubleshooting charts, diagnostic trouble code (DTC) interpretation.

Repair Procedures:

Step-by-step instructions for component removal, replacement, and reinstallation for all major systems.

Diagnostic Procedures:

Using diagnostic tools (like OBD-II scanners), circuit testing, component testing, parameter identification.

Wiring Diagrams:

Detailed electrical schematics for all vehicle systems, including connector pinouts and wire colors.

Specifications And Data:

Torque specifications, clearances, fluid capacities, electrical resistance values, diagnostic data.

Technical Depth

Depth Of Coverage:

Comprehensive coverage from basic maintenance to major component overhaul and advanced diagnostics.

Repair Complexity:

Suitable for DIY mechanics and professional technicians alike, detailing intricate procedures.

📊 Manual Specifications

File Format

File Format:

PDF (Portable Document Format)

Print Quality

Printability:

High-resolution PDF optimized for clear printing, allowing for easy zooming and readability.

Searchability:

Typically includes searchable text layers for quick information retrieval.

Binding Type

Binding Type:

Not Applicable (Digital PDF)

Paper Type

Paper Type:

Not Applicable (Digital PDF)

Compatibility

Operating System Compatibility:

Windows and macOS

⚙️ Engine Specifications

Primary Engine

Engine Option 1 2.3L:

2.3L Duratec I4 (Mazda L3-VE)

Engine Option 1 Specs:

Inline-4, DOHC, 16 valves, 2.3 liters. Horsepower: ~160 hp @ 6200 rpm. Torque: ~150 lb-ft @ 4000 rpm.

Engine Option 2 3.0L:

3.0L Duratec 30 V6 (Ford 'Sable' V6)

Engine Option 2 Specs:

V6, DOHC, 24 valves, 3.0 liters. Horsepower: ~200-215 hp @ 6000 rpm. Torque: ~200-205 lb-ft @ 4000 rpm.

Performance

Engine Design:

Aluminum block and heads, chain-driven camshafts.

Engine Cooling:

Pressurized liquid cooling system with thermostatically controlled fan.

Fuel System

Fuel Delivery:

Electronic Fuel Injection (EFI) with sequential port injection.

Fuel Type:

Unleaded gasoline, minimum 87 octane (87 AKI).

Emission Control:

Catalytic converter, oxygen sensors, evaporative emissions control (EVAP) system.

🔧 Transmission

Standard

Transmission Option 1 4-Cyl:

5-speed Manual Transmission (MTX-75) for 2.3L models.

Optional

Transmission Option 2 4-Cyl AWD:

5-speed Automatic Transaxle (4F50N) for 2.3L AWD models.

Transmission Option 3 V6:

5-speed Automatic Transaxle (AX4N/4F50N) for 3.0L V6 models (available with 2WD and AWD).

Features

Automatic Transmission Features:

SelectShift capability (manual shifting modes) on some automatic transmissions.

AWD System Type:

Active All-Wheel Drive system, typically electronically controlled viscous coupling and rear differential.

Fluid Specifications

Manual Transmission Fluid Spec:

Mercon V or equivalent manual transmission fluid.

Automatic Transmission Fluid Spec:

Mercon V or equivalent automatic transmission fluid (e.g., Motorcraft XT-5QSP).

📐 Dimensions

Exterior

Wheelbase:

107.4 inches (2728 mm)

Length:

191.1 inches (4854 mm)

Width:

72.4 inches (1839 mm)

Height:

57.7 inches (1466 mm)

Wheel Bolt Pattern:

5x114.3 mm (5x4.5 inches)

Wheel Size Standard:

16-inch or 17-inch alloy wheels depending on trim.

Cargo

Trunk Volume:

Approximately 16.0 cubic feet (0.45 m³)

Weights

Curb Weight Range:

3,300 - 3,600 lbs (approximate, varies by engine and drivetrain)

🛡️ Safety Features

Ratings

NHTSA Frontal Crash Rating:

5-Star (Driver and Passenger) for most model years.

NHTSA Side Impact Rating:

5-Star (Front and Rear Passengers).

IIHS Roof Strength Rating:

Active Features

Standard Anti-lock Braking System (ABS)

Traction Control:

Traction Control System (TCS) often standard, especially on AWD models.

Electronic Stability Control:

Electronic Stability Control (ESC), often called AdvanceTrac by Ford, available on many trims.

Passive Features

Airbags Standard:

Front driver and passenger airbags, front side-impact airbags.

Airbags Optional:

Available side curtain airbags for front and rear passengers.

Seatbelts:

3-point front and rear seat belts with pretensioners and load limiters for front seats.

💡 Technology Features

Infotainment

Infotainment System:

Ford's "Audiophile" sound system, optional SiriusXM Satellite Radio, and in-dash CD player.

Connectivity Options:

Auxiliary audio input jack, optional Bluetooth hands-free calling system (SYNC was introduced later in the generation).

Driver Assistance

Cruise Control:

Standard cruise control.

Keyless Entry:

Standard keyless entry keypad on front doors (Ford's signature feature).

Other Convenience:

Power windows and locks, heated seats (optional on higher trims), power adjustable front seats (optional).

🔧 Maintenance

Service Intervals

Oil Change Interval Synthetic:

7,500 miles or 6 months (whichever comes first) with synthetic oil.

Oil Change Interval Conventional:

5,000 miles or 6 months (whichever comes first) with conventional oil, or under severe driving conditions.

Air Filter Replacement:

Every 30,000 miles or as needed based on driving conditions.

Engine Coolant Flush:

Every 100,000 miles or 10 years for the initial change, then every 50,000 miles or 5 years thereafter (using Ford Gold Coolant).

Transmission Fluid Change Automatic:

Every 100,000 miles under normal conditions, or 50,000 miles under severe conditions.

Transmission Fluid Change Manual:

Inspect periodically, replace as needed (often around 100,000 miles).

Spark Plug Replacement Iridium:

100,000 miles for Iridium-tipped spark plugs.

Fluid Specifications

Engine Oil Capacity 2.3L:

4.5 US quarts (4.3 Liters) with filter change (5W-20 recommended).

Engine Oil Capacity 3.0L V6:

5.5 US quarts (5.2 Liters) with filter change (5W-20 recommended).

Engine Coolant Type:

Ford Gold Concentrated Organic Acid Technology (OAT) or equivalent (usually a 50/50 mix with distilled water).

Brake Fluid Type:

DOT 3 or DOT 4 (check specific owner's manual or manual for exact spec).

Known Issues

Common Issue Suspension:

Front control arm bushings wear, leading to knocking noises. Strut mounts can also fail.

Common Issue Engine 2.3L:

Variable Intake Solenoid (VIS) issues can cause rough idle or stalling. Oil leaks from valve cover gaskets.

Common Issue Transmission:

Occasional transmission shifting issues or torque converter shudder, particularly with older automatics. Coolant intrusion into transmissions was a concern on some earlier Ford models, though less prevalent on the Fusion CD3 platform.

Common Issue Electrical:

Window motor failures, HVAC blower motor resistor failures, and occasional issues with door lock actuators.

Common Issue Brakes:

Premature wear of brake pads and rotors can occur, especially with aggressive driving or frequent city driving.

📚 Vehicle History

Brand Heritage

Ford Sedan History:

Ford has a long history of producing successful sedans, dating back to models like the Falcon, Fairlane, LTD, Taurus, and Five Hundred.

Model Evolution

Fusion Launch Year:

2006 Model Year

Fusion Platform Basis:

Developed on the CD3 platform, shared with Mazda (Mazda6) and Volvo (S40, V50), a collaboration from the Premier Automotive Group era.

Fusion Design Inspiration:

Designed to offer a more European driving feel and styling, moving away from some of Ford's previous American sedan designs.

Production

Manufacturing Location:

Flat Rock, Michigan, USA

Production Period Covered By Manual:

2006-2009

Sales Performance Overview:

The Fusion was generally well-received, contributing significantly to Ford's sedan sales in the mid-size segment.

🏆 Awards & Recognition

Recognitions

Initial Reception:

The Ford Fusion was generally praised for its styling, handling, and comfortable ride upon its introduction.

IIHS Top Safety Pick:

Earned 'Good' ratings in IIHS frontal and side-impact crash tests, contributing to its strong safety reputation.

Consumer Reports Ratings:

Varied by model year and specific powertrain, but generally positioned as a competitive option in its segment.