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2009 Ford Fusion CAR/TRUCK REPAIR PROCEDURES AND DIAGRAMS - WHAT Ford REPAIR SHOPS DON'T WANT YOU TO KNOW
Learn how to repair a car or truck, install or remove parts, wire an engine, reset warning lights, replace fuel filter, fix auto body and more. Get Automotix DIY!Select Section
- Technical Service Bulletins
- Specifications
- Brake Service
- Driveline, U-Joint & CV Axles Replacement
- Tire Pressure Monitoring System
- Starter & Alternator Replacement
- Maintenance Lamp Reset
- Radiator & Hose Replacement
- Serpentine Belt Service
BRAKE SERVICE PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
Hydraulic Brake Systems -> Component Service -> Assemble -> Disassemble -> Inspection -> Master Cylinder -> Wheel Cylinders
Vehicle: 2009 Ford Fusion SE 2.3 L4 GAS
Master Cylinder
Disassemble
- Clean outside of master cylinder thoroughly. Drain brake fluid from master cylinder into suitable container.
- Remove stop bolt and pressure control valves.
- Pry up and remove reservoir from master cylinder body.
- Remove fluid control valve.
- Depress primary piston and remove snap ring from retaining groove at open end of bore.
- Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not come out, apply air pressure to secondary outlet port to remove.
Inspection
- Wash components in clean brake fluid only. Use an air hose to bl...
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DRIVELINE, U-JOINT & CV AXLES REPLACEMENT PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
CV AXLE SHAFT, Replace
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
- 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 2009 Ford Fusion AUTOMOBILES
Diagnosis & Testing -> Accessing Diagnostic Trouble Codes -> Clearing Diagnostic Trouble Codes -> Diagnostic Trouble Code Identification -> Intermittent & Poor Connections -> Intermittents -> Poor Connections -> Symptom Test
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
Accessing Diagnostic Trouble Codes
Connect a suitably programmed scan tool to DLC (Data Link Connector) and follow manufacturer's instructions.
Diagnostic Trouble Code Identification
Refer to Fig. , for diagnostic trouble code identification.
Clearing Diagnostic Trouble Codes
Connect a suitably programmed scan tool to DLC (Data Link Connector), and follow manufacturer's instructions.
Symptom Test
Refer to Fig. , for symptom test chart.
Intermittent & Poor Connections
Intermittents
Most intermittents are caused by faulty electrical connections or wiring. Inspect for the following:
- Wirin...
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STARTER & ALTERNATOR REPLACEMENT PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
Starter, Replace
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
- With vehicle in Neutral, position it on a hoist.
- Disconnect battery ground cable.
- If equipped, remove seven screws and underbody cover.
- Remove starter motor solenoid wire nut and position wire aside.
- Position starter motor solenoid battery cable terminal cover aside.
- Remove starter motor solenoid battery cable nut and position cable aside.
- Discon...
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MAINTENANCE LAMP RESET PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
Ford Motor Co. Cars -> Check Fuel Cap Lamp ->
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
The Check Fuel Cap Lamp will illuminate momentarily when the ignition switch is placed in the On position as a bulb check. If the lamp remains...
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RADIATOR & HOSE REPLACEMENT PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
Coolant Hose, Replace -> Lower -> Upper
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
Lower
- Drain coolant into a suitable container.
- Loosen hose clamp connecting hose to radiator.
- Loosen hose clamp connecting hose to thermostat housing.
- Remove hose from vehicle.
- Reverse procedure to...
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SERPENTINE BELT SERVICE PROCEDURES FOR 2009 Ford Fusion AUTOMOBILES
Serpentine Drive Belt, Replace
Vehicle: 2009 Ford Fusion S 2.3 L4 GAS
- Ensure transmission is in Neutral position, then raise and support vehicle.
- Remove mounting bolts...
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TECHNICAL SERVICE BULLETINS FOR 2009 Ford Fusion AUTOMOBILES
OEM TSB listings for most 2009 Ford Fusion cars and light trucks sold in the U.S. from 1985+.
Document: Electronic Automatic Temperature Control (EATC) - Extreme Cold temperature Blank Screen Or Stays In Off Position After Engine Starts Vehicle: 2009 Ford Fusion SEL 2.3 L4 GAS Symptoms: |
Document: 3.0L DOHC - DTC - P0340 AND/OR P0344 Vehicle: 2009 Ford Fusion SEL 3.0 V6 GAS Auto Systems: |
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COMPONENT/PARTS SPECIFICATIONS FOR 2009 Ford Fusion AUTOMOBILES
BRAKE SPECIFICATIONS: Brake drum, rotor, caliper, and related specifications for most 2009 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 2009 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 2009 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 2009 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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