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Ford Fusion CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
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Automotix DIY provides automotive consumers and do it yourselfers; the most comprehensive repair information about Ford Fusion car and truck
repair procedures including Ford engine diagrams, wiring diagrams, repair work estimating measures, technical service bulletins, auto body work
guidance, starter & alternator replacement procedures, serpentine belt replacement procedures, radiator & hose replacement procedures, tune-up &
drivability specifications, quick lube illustrations, preventive maintenance guide, engine light reset instructions, parts removal and install
procedures, fuel filter replacement directions, component location diagrams, air filter locations & replacement instructions, a/c
system specifications, and general auto service procedures. You don't have to be a car mechanic or technician to know how to fix
your Ford Fusion automobile. Try the Automotix DIY solution today!
BRAKE SERVICE PROCEDURES FOR Ford Fusion AUTOMOBILES
Includes anti-lock brakes, disc, drum, power and hydraulic brake services diagnostics and procedures for domestic and imported Ford Fusion cars and light trucks from 1990+.
Disc Brakes -> Rear Disc & Parking Brakes -> Caliper Service -> Assemble -> Cleaning & Inspection -> Crown Victoria, Grand Marquis, Marauder & Town Car -> Disassemble -> Five Hundred, Freestyle, Fusion, Milan, MKZ, Montego, Mustang, Sable, Taurus & Zephyr -> Installation -> LS & Thunderbird -> Overhaul -> Removal -> Replacement
Vehicle: 2007 Ford Fusion SE 3.0 V6 GAS
Replacement
Five Hundred, Freestyle, Fusion, Milan, MKZ, Montego, Mustang, Sable, Taurus & Zephyr
Removal
- Raise and support rear of vehicle, then remove tire and wheel assembly.
- Disconnect brake hose from caliper.
- Remove retaining clip and disconnect parking brake cable from lever arm.
- Remove pinch bolts using open end wrench to hold slider pin in position.
- Lift caliper from anchor plate, then remove slider pins and boots.
Installation
- Apply suitable silicone dielectric compound to slider pins and inside of boots.
- Place slider pins and boots on anchor plate, then position caliper on ancho...
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FUEL FILTER REPLACEMENT PROCEDURES FOR Ford Fusion AUTOMOBILES
Fuel filter replacement procedures with corresponding images for most domestic and imported Ford Fusion cars and light trucks sold in the U.S. for 1980+.
Ford Motor Co. Passenger Cars -> Fuel Shutoff Switch Location -> 2000-06 Fusion, Milan & Lincoln LS
Vehicle: 2006 Ford Fusion SEL 2.3 L4 GAS
The inertia switch...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR Ford Fusion AUTOMOBILES
Includes CV axle, universal joint, and driveline replacement, for domestic and imported Ford Fusion cars and light trucks from 1990+.
CV AXLE SHAFT, Replace
Vehicle: 2010 Ford Fusion SEL 3.0 V6 FLEX
- Remove front tire and wheel.
- Apply brake to keep halfshaft from rotating.
- Remove and discard front wheel hub nut.
- Remove front and rear lower control arm nuts.
- Using a suitable tool, disconnect 2 ball joints. Once pressure is applied to ball joint with a suitable tool, it may be necessary to tap wheel knuckle at ball joint area to separate ball joint from wheel knuckle.
- Using a suitable tool, separate halfshaft from wheel hub. When lower ball joint is separated from wheel knuckle, lower arm may strike outer constant velocity (CV) joint boot with enough force to damage boot cla...
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TIRE PRESSURE MONITORING SYSTEM PROCEDURES FOR Ford Fusion AUTOMOBILES
Description, component locations, reset procedures, relearn procedures, diagnosis and testing, wiring diagrams, component replacement, and identification of vehicles equipped and not equipped with tire pressure monitoring system for most domestic and imported Ford Fusion cars and light trucks sold in the U.S. from mid 1990's+.
Relearn Procedures -> TPMS Sensor Activation -> TPMS Sensor Training
Vehicle: 2008 Ford Fusion SE 3.0 V6 GAS
TPMS Sensor Activation
To conserve battery power, the TPMS sensors will go into a sleep mode after approximately 30 minutes of inactivity. The sensors will not transmit tire pressure information while in sleep mode. The sensors must be activated to transmit the latest tire pressure information.
- Place the ignition switch in the On position.
- Position Ford TPMS activation tool, or equivalent, against the LF tire side wall 180° from the valve stem.
- The TPMS activation tool will flash a green light and sound a beep for each successful response from a TPMS sensor.
- Press the TPMS activat...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR Ford Fusion AUTOMOBILES
Includes starter and alternator replacement procedures for domestic and imported Ford Fusion cars and light trucks from 1990+.
Starter, Replace
Vehicle: 2006 Ford Fusion SE 3.0 V6 GAS
The heavy gauge input lead connected to starter solenoid is hot at all times. Ensure protective cap is installed over terminal and is replaced after service.
- Disconnect battery ground cable.
- Remove air cleaner outlet pipe.
- Remove battery tray.
- Remove starter motor solenoi...
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MAINTENANCE LAMP RESET PROCEDURES FOR Ford Fusion AUTOMOBILES
Maintenance lamp reset procedures with corresponding images for most domestic and imported Ford Fusion cars and light trucks sold in the U.S. from 1990+.
Ford Motor Co. Cars -> Electronic Compass -> 2006-09 Fusion -> Calibration Adjustment -> Zone Adjustment
Vehicle: 2009 Ford Fusion SE 2.3 L4 GAS
Zone Adjustment
- Start the engine.
- Press the INFO button repeatedly until the compass and odometer are displayed. Do not select Trip, DTE, or AFE. The top of the message center must be blank.
- If the compass displays CAL 000000.0 mi instead of heading information, the compass will need to be calibrated.
- Determine compass magnetic zone, Fig. .
- Press and hold the RESET until the message center display changes to show the current zone setting.
- Release the RESET control, then slowly press RESET down again.
- Press the SETUP control repeatedly until the correct zone setting for your geographic l...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR Ford Fusion AUTOMOBILES
Includes radiator, cooling and heater hose replacement procedures for domestic and imported Ford Fusion cars and light trucks from 1990+
Heater Hose, Replace -> Inlet -> Outlet
Vehicle: 2010 Ford Fusion SE 2.5 L4 GAS
Inlet
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to heater core inlet tube.
- Loosen hose clamp connecting hose to coolant outlet adapter.
- Remove hose from vehicle.
- Reverse procedure to install.
Ou...
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SERPENTINE BELT SERVICE PROCEDURES FOR Ford Fusion AUTOMOBILES
Serpentine belt replacement procedures with corresponding images for most domestic and imported Ford Fusion cars and light trucks sold in the U.S. from 1990+.
Serpentine Drive Belt, Replace
Vehicle: 2010 Ford Fusion SEL 3.0 V6 FLEX
- Remove accessory drive belt splash shield.
- Rotate drive be...
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COMPONENT LOCATION DIAGRAMS FOR Ford Fusion AUTOMOBILES
Component location diagrams for most Ford Fusion cars and light trucks sold in the U.S. from 1990+.
 Transmission and Radiator Diagram for 2007 Ford Fusion SE 2.3 L4 GASComponents on diagram: |
 Engine Compartment Diagram for 2008 Ford Fusion SE 3.0 V6 GASComponents on diagram: |
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WIRING DIAGRAMS FOR Ford Fusion AUTOMOBILES
OEM drawn wiring diagrams for most Ford Fusion cars and light trucks sold in the U.S.
 2008 Ford Fusion SE 3.0 V6 GAS Wiring DiagramComponents on diagram: |
 2006 Ford Fusion SEL 3.0 V6 GAS Wiring DiagramComponents on diagram: |
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TECHNICAL SERVICE BULLETINS FOR Ford Fusion AUTOMOBILES
OEM TSB listings for most Ford Fusion cars and light trucks sold in the U.S. from 1985+.
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Document: WATER LEAK - ROOF OPENING PANEL AREA Vehicle: 2006 Ford Fusion SEL 2.3 L4 GAS Symptoms: |
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Document: SPEAKER POP NOISE WITH AUDIOPHILE (NON NAVIGATION) SOUND SYSTEM - REVISED Vehicle: 2008 Ford Fusion SEL 2.3 L4 GAS Symptoms: |
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COMPONENT/PARTS SPECIFICATIONS FOR Ford Fusion AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most Ford Fusion cars and light trucks sold in the U.S. and Canada from 1970+.
- Brake caliper mounting bolt torque
- Brake drum runout, machining, & discard specs
- Minimum brake lining thickness.
- Brake rotor runout, parallelism, machining, discard, & finish specs
A/C SYSTEM SPECIFICATIONS: Air conditioning refrigerant capacity and type as well as lubricant capacity for most Ford Fusion cars and light trucks sold in the U.S. and Canada from 1980+.
- Refrigerant capacity & type, compressor oil viscosity, total system oil capacity & compressor clutch gap
COOLING SYSTEM BLEED: Cooling system bleeder valve identification, bleeder type and bleed procedures for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1986+.
PREVENTIVE MAINTENANCE: Preventive maintenance recommendations and required services for most domestic and imported cars and light trucks sold in the U.S. and Canada from 1980+. Includes severe and routine service schedules
QUICK-LUBE and ILLUSTRATIONS: Fluid recommendations, capacities, drain plug torques, tire data, and severe service recommended preventive maintenance schedules. Information covers most Ford Fusion cars and light trucks sold in the U.S. and Canada from 1980+. Engine and chassis service images.
- Automatic transmission/transaxles capacities, lubricant recommendations
- Differential/final drive capacities, lube recommendations, grades, & viscosities
- Final drive fill & drain plug torques
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Manual transmission/transaxle capacities, lube recommendations, grades, & viscosities
- Number of lubrication fittings & plugs
- Power steering, brake, & clutch fluid recommendations
- Engine oil capacities, API grade recommendations, SAE viscosity recommendations, drain plug torque
- Severe service maintenance & interval recommendations
- Tire sizes, wheel nut/bolt torque, pressures & rim sizes
- Transfer case capacities, lube recommendations, grades, & viscosities
TUNE-UP & DRIVEABILITY SPECIFICATIONS: Most tune-up specifications for most Ford Fusion cars and light trucks sold in the U.S. and Canada from 1980+
- Airflow sensor electrical specifications
- Tensioning specifications for systems with automatic tensioners
- Barometric pressure sensor specs
- Battery group number and cranking performance
- Crankshaft & camshaft position sensor resistance
- Engine compression pressures
- Coolant temperature sensor specs
- Computer advance.
- Diesel fuel temperature sensor resistance.
- Distributor advance specifications
- Ignition pickup coil resistance
- Exhaust gas recirculation temperature sensor resistance
- Engine fastener torque values
- Firing order diagrams
- Fuel system pressures
- Generator (alternator) specs
- Intake air temperature sensor specs
- Ignition coil specifications
- Fuel injector resistance
- Engine idle speeds
- Knock sensor resistance
- Manifold absolute pressure sensor specs
- Mixture control solenoid resistance
- Voltage regulator specs
- Spark plug applications & gaps
- Starter motor electrical specs.
- Tensioning specifications for systems without automatic tensioners
- Throttle body temperature sensor resistance
- Ignition timing in degrees at rpm
- Transmission oil temperature sensor resistance
- Throttle position sensor specs
- Vacuum sensor valve specs
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