Repair manual
Wiring diagrams
Ford Fusion I facelift Repair Manual
Step-by-step repair and maintenance instructions for the Ford Fusion I facelift (2005–2012): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
83sections
763articles
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- OIL PUMP DISASSEMBLY/ASSEMBLY
- Oil Pump Cover Disassembly Note
- Inner Rotor, Outer Rotor Disassembly Note
- CLUTCH COMPONENT DISASSEMBLY/ASSEMBLY
- Snap Ring (3-4 clutch) Disassembly Note
- 3-4 Clutch Piston Disassembly Note
- Reverse Piston Disassembly Note
- One-Way Clutch Retainer Disassembly Note
- Assembly Procedure
- Low and Reverse Brake Piston Disassembly Note
- DIRECT CLUTCH DISASSEMBLY/ASSEMBLY
- Reduction Brake Piston Disassembly Note
- PARKING MECHANISM DISASSEMBLY/ASSEMBLY
- SECONDARY GEAR AND OUTPUT GEAR DISASSEMBLY/ASSEMBLY
- PRIMARY GEAR DISASSEMBLY/ASSEMBLY
- Bearing Disassembly Note
- Bearing Assembly Note
- PRIMARY CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY Primary Control Valve Body Disassembly
- Upper Control Valve Body Disassembly/Assembly
- Main Control Valve Body Disassembly/Assembly
- Primary Control Valve Body Assembly
- SECONDARY CONTROL VALVE BODY DISASSEMBLY/ASSEMBLY Secondary Control Valve Body Disassembly
- Secondary Main Control Valve Body Disassembly/Assembly
- Differential Disassembly
- Roll pin disassembly note
- Differential Assembly
- Diagnostic Strategy
- Preliminary Inspection
- Diagnostics
- Diagnostic Flow Chart
- Road Testing Vehicle
- Shift Point Road Test
- Visual Inspection
- Carry Out On-Board Diagnostic (OBD) (Key ON Engine OFF (KOEO), Key ON Engine Running (KOER))
- On-Board Diagnostic (OBD) with Scan Tool
- Transaxle Drive Cycle Test
- After On-Board Diagnostic (OBD)
- Diagnostic Trouble Code (DTC) Charts
- Shift Solenoid Pre-Diagnosis
- PINPOINT TEST A: SHIFT AND TCC SOLENOIDS (ONLY)
- PINPOINT TEST B: TFT SENSOR
- PINPOINT TEST C: TR SENSOR
- PINPOINT TEST D: ELECTRONIC PCA
- PINPOINT TEST E: ELECTRONIC PCB
- PINPOINT TEST F: INTERMEDIATE SHAFT SPEED SENSOR AND OSS SENSOR
- PINPOINT TEST G: TSS SENSOR
- PINPOINT TEST I: TCM
- Special Testing Procedures
- Line Pressure Test
- Stall Speed Test
- Leakage Inspection
- Leak Check Test
- Leak Check Test With Black Light
- Transmission Fluid Cooler Flow Test
- Diagnosis By Symptom
- Diagnosis by Symptom Index Directions
- Diagnosis by Symptom Index
- Diagnostic Routines
- VECI Decal
- Engine/Evaporative Emission (EVAP) System Information
- Vehicle Emission Control Information (VECI) Acronym Definitions
- Engine Control Components
- Accelerator Pedal Position (APP) Sensor
- Air Conditioning (A/C) Clutch Relay (A/CCR)
- Air Conditioning (A/C) Cycling Switch
- Air Conditioning Evaporator Temperature (ACET) Sensor
- Air Conditioning (A/C) High Pressure Switch
- Air Conditioning Pressure (ACP) Transducer Sensor
- Brake Pedal Position (BPP) Switch
- Brake Pedal Switch (BPS)/Brake Deactivator Switch
- Camshaft Position (CMP) Sensor
- Canister Vent (CV) Solenoid
- Check Fuel Cap Indicator
- Clutch Pedal Position (CPP) Switch
- Coil On Plug (COP)
- Coil Pack
- Cooling Fan Clutch
- Crankshaft Position (CKP) Sensor
- Cylinder Head Temperature (CHT) Sensor
- Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor
- Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor - Tube Mounted
- Electric Exhaust Gas Recirculation (EEGR) Valve
- Electronic Throttle Actuator Control (TAC)
- Electronic Throttle Body (ETB) Throttle Position Sensor
- Engine Coolant Temperature (ECT) Sensor
- Engine Oil Temperature (EOT) Sensor
- Evaporative Emission (EVAP) Canister Purge Valve
- Exhaust Gas Recirculation (EGR) System Module (ESM)
- Exhaust Gas Recirculation (EGR) Vacuum Regulator Solenoid
- Exhaust Gas Recirculation (EGR) Valve
- Fan Control
- Fan Speed Sensor (FSS)
- Fuel Injectors
- Fuel Level Input (FLI)
- Fuel Pump (FP) Module
- Fuel Pump (FP) Module and Reservoir
- Fuel Rail Pressure Temperature (FRPT) Sensor
- Fuel Rail Pulse Damper
- Fuel Tank Pressure (FTP) Sensor
- Heated Oxygen Sensor (HO2S)
- Idle Air Control (IAC) Valve
- Inertia Fuel Shutoff (IFS) Switch
- Intake Air Temperature (IAT) Sensor
- Intake Manifold Tuning Valve (IMTV)
- Knock Sensor (KS)
- Manifold Absolute Pressure (MAP) Sensor
- Mass Air Flow (MAF) Sensor
- Output Shaft Speed (OSS) Sensor
- Power Steering Pressure (PSP) Sensor
- Power Steering Pressure (PSP) Switch
- Power Take-Off (PTO) Switch and Circuits
- Powertrain Control Module - Vehicle Speed Output (PCM-VSO)
- Secondary Air Injection (AIR) Bypass Solenoid
- Secondary AIR Diverter Valve
- Secondary AIR Pump
- Starter Motor Request (SMR) Circuit
- Throttle Position (TP) Sensor
- Transmission Control Indicator Lamp (TCIL)
- Transmission Control Switch (TCS)
- Universal HO2S
- Vehicle Speed Sensor (VSS)
- Modifications to OBD Vehicles
- Powertrain Control Module (PCM)
- Fuel Pump Driver Module (FPDM)
- Keep Alive Memory (KAM)
- Integrated Electronic Ignition System
- Electronic Throttle Control Reference Voltage (ETCREF)
- Electronic Throttle Control Return (ETCRTN)
- Gold Plated Pins
- Keep Alive Power (KAPWR)
- Mass Air Flow (MAF) Return
- Power Ground (PWR GND)
- Signal Return (SIG RTN)
- Variable Reluctance Sensor Return (VRSRTN)
- Vehicle Buffered Power (VBPWR)
- Vehicle Power (VPWR)
- Vehicle Reference Voltage (VREF)
- Adaptive Airflow
- Computer Controlled Shutdown
- Engine RPM/Vehicle Speed Limiter
- Fail-Safe Cooling Strategy
- Failure Mode Effects Management (FMEM)
- Flash Electrically Erasable Programmable Read Only Memory (EEPROM)
- Fuel Trim
- High Speed Controller Area Network (CAN)
- Idle Air Trim
- Multiplexing
- Multiplexing Implementation
- Malfunction Indicator Lamp (MIL)
- Catalytic Converter
- Light Off Catalyst
- Three-Way Catalyst (TWC) Conversion Efficiency
- Exhaust System
- Underbody Catalyst
- Three-Way Catalytic (TWC) Converter
- Exhaust Manifold Runners
- Exhaust Pipes
- Muffler
- Enhanced Evaporative Emission (EVAP) System
- Differential Pressure Feedback Exhaust Gas Recirculation (EGR) System
- Electric Exhaust Gas Recirculation (EEGR) System
- Electronic Returnless Fuel System (ERFS)
- Fuel Pump Control - ERFS
- Fuel Pump Monitor (FPM) - ERFS
- Mechanical Returnless Fuel System (MRFS)
- Fuel Pump Control - MRFS
- Fuel Pump Monitor (FPM) - MRFS
- Fuel Filters
- Engine Crank/Engine Running
- CMP FMEM
- Intake Manifold Runner Control (IMRC) Electric Actuated System
- Intake Manifold Runner Control (IMRC) Vacuum Actuated System
- Intake Manifold Tuning Valve (IMTV) System
- Heated Tubes
- PCV Valves
- Secondary AIR System
- Supercharger Bypass (SCB) System
- Charge Air Cooler (CAC) System
- Electronic Throttle Body (ETB)
- Electronic Throttle Control (ETC) System Strategy
- APP and TP Sensor Inputs
- Electronic Throttle Actuator Control (TAC) Output
- Variable Camshaft Timing (VCT) System
- Catalyst Efficiency Monitor
- Cold Start Emission Reduction Component Monitor
- Cold Start Emission Reduction System Monitor
- Comprehensive Component Monitor (CCM)
- Electric Exhaust Gas Recirculation (EEGR) System Monitor
- Evaporative Emission (EVAP) Leak Check Monitor
- Engine On EVAP Leak Check Monitor
- Engine Off Natural Vacuum (EONV) EVAP Leak Check Monitor
- Exhaust Gas Recirculation (EGR) System Monitor - Differential Pressure Feedback EGR and EGR System Module (ESM)
- Fuel System Monitor
- Heated Oxygen Sensor (HO2S) Monitor
- Misfire Detection Monitor
- Positive Crankcase Ventilation (PCV) System Monitor
- Secondary Air Injection (AIR) System Monitor
- Thermostat Monitor
- Variable Camshaft Timing (VCT) Monitor
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Inspection and Verification
- DTC Charts
- Symptom Chart
- Pinpoint Test A: Both Low Beams Are Inoperative
- Pinpoint Test B: Both High Beams Are Inoperative
- Pinpoint Test C: One Low Beam Headlamp Is Inoperative
- Pinpoint Test D: One High Beam Headlamp Is Inoperative
- Pinpoint Test E: The Headlamps Are On Continuously
- Pinpoint Test F: The Flash-To-Pass Feature Is Inoperative
- Pinpoint Test G: The AUTOLAMPS Are Inoperative
- Pinpoint Test H: The AUTOLAMPS Are On Continuously
- Pinpoint Test I: All The Stoplamp Are Inoperative
- Pinpoint Test J: One Or More Stoplamp Are Inoperative
- Pinpoint Test K: The Stoplamp Are On Continuously
- Pinpoint Test L: The Turn Signal Lamps Are Inoperative
- Pinpoint Test M: The Turn Signal Lamps Are Always On
- Pinpoint Test N: One Turn Signal/Hazard Lamp Is Inoperative/Always On
- Pinpoint Test O: The Hazard Lamps Are Inoperative/Always On
- Pinpoint Test P: One Or More Parking, Rear or License Plate Lamps Is Inoperative
- Pinpoint Test Q: The Parking, Rear Or License Plate Lamps Are On Continuously
- Pinpoint Test R: The Fog Lamps Are Inoperative
- Pinpoint Test S: An Individual Fog Lamp Is Inoperative
- Pinpoint Test T: The Fog Lamps Are On Continuously
- Pinpoint Test U: The Reversing Lamps Are Inoperative
- Pinpoint Test V: An Individual Reversing Lamp Is Inoperative
- Pinpoint Test W: The Reversing Lamps Are On Continuously
- PINPOINT TEST X: THE DAYTIME RUNNING LAMPS (DRL) ARE INOPERATIVE
- Inspection and Verification
- DTC Charts
- Symptom Chart
- Pinpoint Test A: The PCM Does Not Respond To The Scan Tool
- Pinpoint Test B: The Transmission Control Module (TCM) Does Not Respond To The Scan Tool
- Pinpoint Test C: The ABS module Does Not Respond To The Scan Tool
- Pinpoint Test D: The Restraints Control Module (RCM) Does Not Respond To The Scan Tool
- Pinpoint Test E: The 4X4 Control Module Does Not Respond To The Scan Tool
- Pinpoint Test F: The Occupant Classification System Module (OCSM) Does Not Respond To The Scan Tool
- Pinpoint Test G: The Instrument Cluster (IC) Does Not Respond To The Scan Tool
- Pinpoint Test H: The Smart Junction Box (SJB) Does Not Respond To The Scan Tool
- Pinpoint Test I: The Heating Ventilation Air Conditioning (HVAC) Module Does Not Respond To The Scan Tool
- Pinpoint Test J: The Parking Aid Module (PAM) Does Not Respond To The Scan Tool
- Pinpoint Test K: The Audio Control Module (ACM) Does Not Respond To The Scan Tool
- PINPOINT TEST L: PINPOINT TEST L: THE AUDIO DIGITAL SIGNAL PROCESSING (DSP) MODULE DOES NOT RESPOND TO THE SCAN TOOL
- PINPOINT TEST M: THE SATELLITE DIGITAL AUDIO RECEIVER SYSTEM (SDARS) MODULE DOES NOT RESPOND TO THE SCAN TOOL
- PINPOINT TEST N: THE DRIVER DOOR MODULE (DDM) DOES NOT RESPOND TO THE SCAN TOOL
- Pinpoint Test O: The Driver Seat Module (DSM) Does Not Respond To The Scan Tool
- PINPOINT TEST P: PINPOINT TEST P: THE DUAL CLIMATE CONTROL SEAT MODULE (DCSM) DOES NOT RESPOND TO THE SCAN TOOL
- Pinpoint Test Q: The Accessory Protocol Interface Module (APIM) Does Not Respond To The Scan Tool
- Pinpoint Test R: No Medium Speed Controller Area Network (MS-CAN) Communication, All Modules Are Not Responding
- PINPOINT TEST S: INTERMITTENT NO MEDIUM SPEED CONTROLLER AREA NETWORK (MS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST
- Pinpoint Test T: No High Speed Controller Area Network (HS-CAN) Communication, All Modules Are Not Responding
- PINPOINT TEST U: INTERMITTENT NO HIGH SPEED CONTROLLER AREA NETWORK (HS-CAN) COMMUNICATION, ONE OR MORE MODULES ARE NOT RESPONDING DURING NETWORK TEST
- Pinpoint Test V: No Power To The Scan Tool
- Diagnostic Instructions
- Diagnostic Test Options
- Self Test/On-Demand
- Self Test/Continuous Memory and Clear DTCs
- Diagnosing Customer Concerns With On-Demand DTCs
- Diagnosing Customer Concerns With Continuous Memory DTCs
- Diagnostic Test Modes
- Zero Seat Weight Test
- Inspection and Verification
- Symptom Chart
- Pinpoint Test A: The Air Bag Warning Indicator is Illuminated Continuously
- Pinpoint Test B: DTC B1884 - PAD Warning Lamp Circuit Failure
- Pinpoint Test C: DTC B1890 - PAD Warning Lamp Circuit Short to Battery
- Pinpoint Test D: DTC B2290 - Occupant Classification System Fault
- Pinpoint Test E: DTC B2292 - Restraint System - Seatbelt Pretensioner Fault
- Pinpoint Test F: DTC B2293 - Restraint System - Air Bag Fault
- Pinpoint Test G: DTC B2294 - Restraint System - Curtain Fault
- Pinpoint Test H: DTC B2295 - Restraint System - Side Air Bag Fault
- Pinpoint Test I: DTC B2296 - Restraint System - Impact Sensor Fault
- Pinpoint Test J: DTC B2434 - Drivers Seat Belt Buckle Switch Circuit Short to Ground
- Pinpoint Test K: DTC B2435 - Drivers Seat Belt Buckle Switch Resistance Out of Range
- Pinpoint Test L: DTC B2438 - Passengers Seat Belt Buckle Switch Short to Ground
- Pinpoint Test M: DTC B2439 - Passengers Seat Belt Buckle Switch Resistance Out of Range
- Pinpoint Test N: DTC B2691 - Seat Belt Buckle Switch Circuit Fault, Front Driver's Side
- Pinpoint Test O: DTC B2692 - Front Passenger's Seat Belt Buckle Switch Circuit Fault
- Pinpoint Test P: DTC B2792 - Cross Link Between Firing Loops
- PINPOINT TEST P: DTC B2792 - CROSS LINK BETWEEN FIRING LOOPS FAULT
- Pinpoint Test Q: DTC B229A - Occupant Classification System Contamination (Rail Type System)
- PINPOINT TEST Q: DTC B229A - OCCUPANT CLASSIFICATION SYSTEM CONTAMINATION
- Pinpoint Test R: DTC B229B - Occupant Classification System Obstruction
- Pinpoint Test S: DTC C1946 - Front Driver's Seat Track Position Switch Circuit Open
- Pinpoint Test T: DTC C1947 - Front Driver's Seat Track Position Switch Circuit Short to Ground
- Pinpoint Test U: DTC C1948 - Front Driver's Seat Track Position Switch Circuit Resistance Out of Range
- Pinpoint Test V: DTC C1981 - Front Driver's Seat Track Position Switch Circuit Fault
- Occupant Classification Sensor (OCS) System Zero Seat Weight Test
- Engine Controls - Introduction (Except Diesel & Hybrid) 3
- Engine Controls - Symptom Charts (Except Diesel & Hybrid) 2
- Engine Controls - Pinpoint Tests (Except Diesel & Hybrid)
- Engine Controls - Diagnostic Methods (Except Diesel & Hybrid) 5
- Engine Controls - Description and Operation (Except Diesel & Hybrid) 6
- Engine Controls - Powertrain DTC Charts and Descriptions (Except Diesel & Hybrid)