Ford Fusion Manuals

Ford Fusion: Body Repairs - Vehicle Specific Information and Tolerance Checks / Body and Frame. Description and Operation

Body

Ford Fusion. Body and Frame. Description and Operation  WARNING: Electric vehicles damaged by a crash may have compromised high voltage safety systems and present a potential high voltage electrical shock hazard. Exercise caution and wear appropriate Personal Protective Equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all metallic jewelry, including watches and rings. Isolate the HV system as directed by the Ford Emergency Response Guide for the vehicle. Failure to follow these instructions may result in serious personal injury or death.

Ford Fusion. Body and Frame. Description and Operation  WARNING: Never install used or reconditioned parts (as specified below) from pre-owned, salvaged or damaged vehicles. The use of such parts could lead to serious injury. Never use non-Ford parts or accessories for completing repairs. Ford Motor Company does not approve or recognize body and structural repair procedures, tools, parts or anything but new genuine Ford equipment. Ford cannot attest to the safety, quality, durability or legality of non-Ford parts or accessories. Use of such parts could lead to serious personal injury as they may contain damage which is not visible. Ford does not approve use of the following: Salvaged or used parts Major body clips or assemblies from salvage vehicles Aftermarket structural or body components Salvaged or reconditioned wheels Used Supplemental Restraint System (SRS) components air bags restraint system modules safety belts, buckles or retractors crash sensors Returning a vehicle to pre-accident condition can only be assured if repair procedures are carried out by skilled technicians using new genuine Ford parts and Ford-approved methods. Structural component repair procedures approved by Ford, using genuine Ford parts, have been validated by Ford Motor Company engineers. Ford Motor Company does not endorse, cannot attest to, and makes no representations regarding structural repairs (frames, rails, aprons and body panels) carried out using non-genuine Ford Motor Company parts or non-Ford-approved methods. In particular, Ford makes no representations that the vehicle will meet any crash safety or anti-corrosion performance requirement. Such parts and methods have not been tested by Ford, and may not meet Ford's requirements for safety, performance, strength, quality, durability and corrosion protection. Ford Motor Company bears no responsibility or liability of any kind if repairs are performed using alternative structural component repair procedures and/or parts.

The body consists of the following:

  • High-Strength Low Alloy (HSLA), high-strength, ultra high strength steel (UHSS) and mild steels
  • Roof outer panel constructed of bake hardened (BH) steel
  • Aluminum hood
  • Steel luggage compartment lid
  • Body side outer panels constructed of mild steel
  • Dual Phase Steel (DP) in select body structure components
  • Bolted, removable front fenders, hinged doors and hood
  • Dent resistant steel fenders
  • Front and rear subframe assemblies housing suspension and steering components
  • Underbody components constructed of mild, dual-phase and high-strength steels
  • Mastic pad material used on floor pan and roof panel for sound deadening

Body Dimensions

Body Margins - Front Panels

NOTE: All margins must be parallel within 1.0 mm unless otherwise noted for sheet metal-to-sheet metal interfaces only.

NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.

Ford Fusion. Body and Frame. Description and Operation
Item Description Margin Specification Flushness Specification
1 Hood-to-fascia 3.5 mm ± 2.0 mm (Parallelism within 0.0 mm ± 2.0 mm) 0.75 mm ± 2.2 mm
2 Headlamp-to-hood 5.0 mm 1.9 mm ± 2.2 mm
3 Hood-to-fender 3.0 mm ± 1.7 mm (Hood overflush to fender) 0.3 mm ± 1.8 mm
4 Hood-to-fender 3.0 mm ± 1.7 mm (Hood underflush to fender) 2.4 mm ± 1.8 mm
5 Hood-to-A-pillar 4.1 mm ± 1.9 mm 0.5 mm ± 1.8 mm
6 Hood-to-A-pillar 3.2 mm ± 1.9 mm 0.5 mm ± 2.4 mm
7 Fender-to-A-pillar 3.0 mm ± 1.5 mm
8 Fender-to-front door 3.4 mm ± 1.5 mm 0.75 mm ± 1.5 mm
9 Headlamp-to-front fender 2.0 mm ± 1.9 mm 0.0 mm ± 2.0 mm
10 Fascia-to-fender 0.0 mm ± 0.5 mm 0.75 mm ± 1.5 mm
11 Headlamp-to-fascia 2.0 mm ± 1.2 mm

Body Margins - Fender Triangle

NOTE: All margins must be parallel within 1.0 mm unless otherwise noted for sheet metal-to-sheet metal interfaces only.

NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.

Ford Fusion. Body and Frame. Description and Operation
Item Description Margin Specification Flushness Specification
1 A-pillar-to-fender triangle 2.0 mm (Margin varies 8.6 mm to 9.1 mm between point A and point B) Flushness varies from 4.6 mm to 3.1 mm between point A and point B
2 Glass run-to-division bar 0.7 mm ± 0.0 mm
3 A-pillar-to-glass run channel 9.0 mm ± 2.7 mm 2.7 mm (Flushness varies 3.1 mm to 1.3 mm between point C and point D)
4 Fender triangle-to-glass run channel 3.0 mm ± 1.7 mm 0.0 mm ± 2.7 mm
5 Fender triangle-to-fixed glass 4.5 mm ± 2.7 mm 1.5 mm ± 2.7 mm
6 Fender triangle-to-belt moulding 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm

Body Margins - Side Panels

NOTE: All margins must be parallel within 1.0 mm unless otherwise noted for sheet metal-to-sheet metal interfaces only.

NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.

Ford Fusion. Body and Frame. Description and Operation
Item Description Margin Specification Flushness Specification
1 Front door-to-bodyside 9.0 mm ± 2.7 mm 1.0 mm ± 2.7 mm
2 Bodyside-to-roof 6.0 mm (Reference)
3 Front door glass run-to-rear door glass run 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
4 Rear quarter glass moulding-to-rear glass run 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
5 Rear door C-pillar applique-to-quarter glass 4.5 mm ± 2.7 mm 5.0 mm ± 2.7 mm
6 Rear door belt moulding-to-rear quarter glass moulding 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
7 Rear door-to-bodyside quarter panel 3.4 mm ± 1.5 mm 0.0 mm ± 1.5 mm
8 Rear door-to-rocker moulding 6.0 mm (Reference) - 3.0 mm (Reference)
9 Front door-to-rear door 3.4 mm ± 1.5 mm 0.75 mm ± 1.5 mm
10 Front door belt moulding-to-rear door belt moulding 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
11 Front door applique-to-rear door applique 4.5 mm ± 2.7 mm 0.0 mm ± 2.7 mm
12 Front door-to-rocker moulding 6.0 mm (Reference) - 3.0 mm (Reference)

Body Margins - Rear Panels

NOTE: All margins must be parallel within 1.0 mm unless otherwise noted for sheet metal-to-sheet metal interfaces only.

NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.

Ford Fusion. Body and Frame. Description and Operation
Item Description Margin Specification Flushness Specification
1 Bodyside-to-decklid 3.0 mm ± 1.5 mm 0.75 mm ± 2.0 mm
2 Luggage compartment lid-to-applique 0.7 mm + 1.2 mm / -0.7 mm 0.0 mm ± 1.4 mm
3 Rear closure applique-to-rear closure chrome applique 1.0 mm ± 1.0 mm 3.2 mm ± 1.4 mm
4 Luggage compartment lid-to-fascia 6.0 mm ± 3.5 mm
5 Luggage compartment lid lower finish panel-to-fascia side 5.0 mm ± 3.3 mm 2.0 mm ± 3.5 mm

Body Margins - Rear Spoiler and Lamps

NOTE: All margins must be parallel within 1.0 mm unless otherwise noted for sheet metal-to-sheet metal interfaces only.

NOTE: Unless otherwise indicated, margin dimensions apply to RH and LH side of vehicle.

Ford Fusion. Body and Frame. Description and Operation
Item Description Margin Specification Flushness Specification
1 Rear lamp-to-bodyside 1.5 mm ± 1.2 mm
2 Spoiler-to-luggage compartment lid 1.1 mm ± 1.0 mm 2.5 mm ± 2.0 mm
3 Spoiler-to-luggage compartment lid 0.5 mm 3.2 mm ± 2.0 mm
4 Luggage compartment lid upper-to-luggage compartment lid lamp 1.5 mm ± 1.2 mm
5 Rear closure chrome applique-to-luggage compartment lid lamp 1.6 mm ± 1.6 mm 0.0 mm ± 1.6 mm
6 Rear closure chrome applique-to-luggage compartment lid lamp 1.0 mm ± 1.0 mm
7 Luggage compartment lid handle-to-luggage compartment lid lamp lens 1.3 mm + 1.4 mm / - 1.3 mm
8 Luggage compartment lid lamp-to-luggage compartment lid lower finish panel 2.0 mm ± 2.0 mm
9 Luggage compartment lid lamp-to-rear lamp 3.5 mm ± 2.8 mm 1.5 mm ± 2.7 mm (Luggage compartment lid lamp underflush)
10 Luggage compartment lid lamp-to-rear lamp 3.5 mm ± 2.8 mm 1.0 mm ± 2.7 mm
11 Bodyside lower-to-luggage compartment lid 3.3 mm ± 1.5 mm 1.0 mm ± 2.0 mm
12 Rear lamp-to-rear fascia 2.0 mm ± 1.9 mm
13 Bodyside-to-rear fascia 0.5 mm 0.75 mm ± 1.5 mm
14 Fuel door-to-bodyside 2.2 mm ± 1.2 mm 1.0 mm ± 1.4 mm

Under Hood Dimensions

NOTE: All measurements are on center unless otherwise indicated.

Ford Fusion. Body and Frame. Description and Operation

Front Door Opening Dimensions

NOTE: All measurements are on center unless otherwise indicated.

Ford Fusion. Body and Frame. Description and Operation

Luggage Compartment Opening Dimensions

NOTE: All measurements are on center unless otherwise indicated.

Ford Fusion. Body and Frame. Description and Operation

Under Body Measurements

NOTE: All measurements are on center unless otherwise indicated.

Ford Fusion. Body and Frame. Description and Operation

Datum Height Dimensions

NOTE: Measurements indicated below door frame openings obtained from center floor rail.

Ford Fusion. Body and Frame. Description and Operation

    Body Repairs - Vehicle Specific Information and Tolerance Checks

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    Vehicle Specific Body Construction. Description and Operation

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    Other information:

    Ford Fusion 2013–2020 Service Manual: Receiver Drier - 2.0L EcoBoost (184kW/250PS) – MI4. Removal and Installation


    Removal NOTICE: During the removal of components, cap, tape or otherwise appropriately protect all openings to prevent the ingress of dirt or other contamination. Remove protective materials prior to installation. NOTE: Removal steps in this procedure may contain installation details...

    Ford Fusion 2013–2020 Service Manual: Rear Seat Cushion Cover. Removal and Installation


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    Categories

    Power Door Locks

    The power door lock control is on the driver and front passenger door panels.

    Ford Fusion. Power Door Locks

    Unlock. Lock.

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