Ford Fusion 2006-2009 Service & Repair Manual

Description

The complete factory service and repair documentation for the 2006, 2007, 2008 and 2009 Ford Fusion — 155 documents and 10,321 pages of dealer-level procedure, delivered as a searchable PDF the moment you pay. It covers the car end to end: step-by-step removal, installation and overhaul procedures, specifications and torque figures, diagnostic routines and pinpoint tests, trouble-code charts, and wiring and connector information for every system on the vehicle.

About the 2006–2009 Fusion

The first-generation Fusion is the car that restarted Ford’s midsize saloon line. Launched for 2006 and built at Hermosillo in Mexico, it sat on the CD3 platform Ford developed from the Mazda6 — a genuinely good chassis that gave the Fusion the sharpest steering and body control Ford had put under a family four-door in years, and earned it a reputation for reliability the outgoing Taurus never had. It arrived as a trio: the Fusion, the Mercury Milan, and the Lincoln Zephyr, which was renamed MKZ for 2007 and picked up the larger 3.5L V6. All-wheel drive joined the range for 2007. Mechanically the cars are the same vehicle under different skins, which is why the factory documentation treats them together — and why one manual covers all four.

Vehicles covered

Ford Fusion, Mercury Milan, Lincoln Zephyr and Lincoln MKZ — the first-generation CD3 cars. The Zephyr name was used for 2006 only and became the MKZ from 2007.
Model years: 2006, 2007, 2008, 2009

Engines documented

• 2.3L Duratec four-cylinder — full mechanical section plus air intake, fuel controls, ignition, electronic engine controls, emission controls and accessory drive
• 3.0L Duratec V6 — full mechanical section plus air intake, fuel charging, ignition, electronic engine controls, emission controls and accessory drive
• 3.5L Duratec V6 — the Lincoln engine, documented across ignition, accessory drive and cooling

Transmission & drivetrain

The FNR5 five-speed automatic and the AW21 transaxle both get their own sections, with diagnosis, external control, in-vehicle service, overhaul and cooling-circuit procedures. Front-wheel drive and all-wheel drive are both documented — driveline system, driveshaft, transfer case, rear differential, and front and rear drive axle shafts.

What’s inside

Engine mechanical and engine management, fuel system and tank, exhaust and emissions including EVAP, engine cooling, the automatic transmissions plus the manual gearbox and clutch, driveline and axles, brakes with anti-lock and the hydraulic and power-assist circuits, parking brake, suspension front and rear, steering system and column, wheels and tyres, heating and air conditioning, charging, starting and the alternator, restraints and airbags, seat belts, anti-theft, instrument cluster and message centre, entertainment and information systems, exterior and interior lighting, windows, mirrors, sunroof, wipers and washers, body panels, bumpers and trim, plus the maintenance schedule and the full Ford and generic trouble-code references.

The electrical coverage includes wiring diagrams, schematics, connector information and electrical component locations, along with fuse identification and pinpoint tests — so you can trace a circuit end to end rather than guessing at it.

Common issues this manual helps you tackle

These cars have a well-documented set of trouble spots. This manual carries the factory procedures for the systems behind them.

• Long brake pedal from the ABS hydraulic control unit — the subject of Ford safety recall 19S54 (NHTSA 19V904000) and follow-up programme 21N11, covering 2006–2010 Fusion, Milan, Zephyr and MKZ. Valves inside the HCU can react with corrosion inhibitors in some brake fluids and fail to close, so the pedal travels further before the car stops. Brakes are the single most-complained-about system on these cars. The anti-lock brake, hydraulic brake, power brake and brake system general information sections cover HCU diagnosis, bleeding, fluid specification and the full replacement procedure.
• Takata frontal airbag inflators — multiple recalls apply across the range (NHTSA 21V158000, 18V046000, 17V024000 and 16V384000), covering driver and passenger inflators. The replacement itself is free dealer work and should be done there — but if you are going anywhere near the steering column, instrument panel or seats, the airbag and restraints sections give you the factory disarm, handling and re-arm procedure so you do not set one off on the bench.
• FNR5 automatic slipping, flaring or engaging late — transmission complaints on these cars cluster around slipping and jerking, and around a high-revving delay before the car takes up drive. The FNR5 section runs from fluid level and condition through solenoid and pressure testing to full overhaul, with the transmission control and external-control sections for the electronic side and a dedicated cooling section for the cooler and lines.
• Coil-on-plug failure and misfire codes — burnt-out coils are among the most expensive engine complaints reported on these cars, and they present as a rough idle, a flashing check-engine light and a cylinder-specific misfire code. Each engine has its own ignition section, backed by electronic engine controls, component testing, basic troubleshooting, pinpoint tests and the Ford and generic trouble-code charts.
• 3.5L V6 internal water pump — the 3.5L Duratec drives its water pump off the timing chain, inside the engine. When the seal lets go, coolant goes into the oil rather than onto the driveway, and the warning you get is a dropping coolant level rather than a puddle. The engine cooling section documents the 3.5L circuit, pressure testing and coolant specification, so you can catch it before it takes the bearings with it.
• Exterior lighting and turn-signal faults — dead turn signals and lighting gremlins are a recurring complaint on the earlier cars, and they are almost always a switch, a connector or a ground rather than a bulb. The exterior lighting, steering column switch, fuse and electrical component locator sections, together with the wiring diagrams and connector information, let you test the circuit properly instead of replacing parts on spec.

Format

Searchable PDF — 155 documents, 10,321 pages, supplied as a single download. It opens on Windows, macOS, Linux, iOS, Android and any other device with a PDF reader, needs no special software, and once you have downloaded it, it is yours to keep and to print. Delivery is instant: the download link is on your order confirmation the moment payment clears.

Frequently asked questions

Will this cover my car? If it is a 2006, 2007, 2008 or 2009 Ford Fusion, it will. The same manual covers the Mercury Milan across those years, the Lincoln Zephyr for 2006 and the Lincoln MKZ from 2007 — they are the same car underneath, and the factory documentation treats them as one family.

I have a 2010 Fusion. Is this the right manual? No — you need a different one. Ford substantially reworked the Fusion for 2010: the 2.3L four was replaced by the 2.5L, and a six-speed automatic came in alongside it. This manual documents the 2006–2009 hardware, so the engine, transmission and much of the electrical content will not match a 2010 or later car.

Is it really searchable? Yes — the service sections are proper text PDFs, so you can search for a part name, a torque figure or a trouble code and jump straight to it. The wiring diagram sheets are supplied as scanned drawings, so you read those as diagrams and zoom in on them rather than searching them by keyword.

Does it cover all-wheel drive? Yes. The driveline system, driveshaft, transfer case, rear differential and front and rear drive axle shaft sections are all included, so the AWD Fusion, Milan and MKZ are covered as fully as the front-drive cars.

Is this enough to do real work, or just an owner’s guide? It is dealer-level service documentation — the removal, installation, disassembly and overhaul procedures with the specifications and torque figures that go with them, plus diagnostics and pinpoint tests. The 2006 and 2007 owner handbooks are included as well, but the bulk of it is workshop material.