System Subsystem # Subsystem Name Subsystem Description Ford Fusion Gas Engine Ford Fusion Hybrid

000000 Complete Vehicle System

010000 Body Systems (Note: Includes Instrument Panel/P, Body HVAC, 

and Seating Subsystems)

010100 Body Structure Subsystem Cross Vehicle Framing parts, rear floor pan, roof and Xmembers, etc Similar - requires additional disassembly Similar - requires additional disassembly

010200 Front End Subsystem Front Structure Similar - requires additional disassembly Similar - requires additional disassembly

010300 Body Closures Subsystem Same Same

010400 Second Unit Body Subsystem Same Same

010500 Interior Trim and Ornamentation 

Subsystem Same Same

010600 Sound and Heat Control Subsystem 

(Body) N/A Additional Insulation under rear seat

010700 Sealing Subsystem Same Same

010800 Exterior Trim and Ornamentation 

Subsystem No Engine Cover Engine Cover

010900 Rear View Mirrors Subsystem Same Same

011000 Seating Subsystem Rear Seating Typical foam rear bench seat

Rear seat includes integral ducting for 

battery pack cooling

011100 Glass (Glazing), Frame and Mechanism 

Subsystem Same Same

011200 Instrument Panel and Console 

Subsystem Instrument Panel Main Molding,. Switch Packs I/P Unique Unique

011400 Handles, Locks, Latches and 

Mechanisms Subsystem Same Same

011600 Wipers And Washers Subsystem Washer bottle fill relocated for packaging

011700 Convertible Top and Roof Opening Panel 

Subsystem N/A N/A

011800 Body Paint Subsystem Same Same

011900 Bumpers Subsystem Same Same

012000 Occupant Restraining Device Subsystem Same Same

012300 Front End Modules Radiator Close out differences, Requires 

Additional Disassembly

Radiator Close out differences, Requires 

Additional Disassembly

012400 Rear End Modules Requires Additional Disassembly Requires Additional Disassembly

012500 Liftgate Modules N/A N/A

012600 Pickup Box Modules N/A N/A

012700 Cockpit Modules Requires Additional Disassembly Requires Additional Disassembly

012800 Wiper and Cowl Modules Same Same

012900 Overhead Module Same Same

013000 Carpet Modules Requires Additional Disassembly, Rear 

Trunk Trim Differences

Requires Additional Disassembly, Rear 

Trunk Trim Differences

Trunk load floor/carpet typical Same as V6 except reduced length

Rear Seats fold down with cable release

rear seats fold down - no cable release or 

trim cover

Unique Trunk Side Close Outs Unique Trunk Side Close Outs

013100 Package Tray Modules Same Same

013300 Door Modules Same Same

013400 Floor and Tunnel Console Modules Same Same

020000 Frame And Mounting System

020100 Frame Subsystem Front Sub-Frame Requires Additional Disassembly Requires Additional Disassembly

020200 Body Mounting Subsystem Requires Additional Disassembly Requires Additional Disassembly

Major Differences in rear seats, and in trunk trim, some minor differences related 

to packaging constraints

Minor Differences in mounts additional investigation required
020300 Engine/Transmission Mounting 

Subsystem Minor Differences in Mounts Minor Differences in Mounts

020400 Towing and Coupling Attachments 

Subsystem N/A N/A

020500 Spare Tire Mounting (Chassis) 

Subsystem Same Same

020800 Rolling Chassis Modules N/A N/A

030000 Engine System (Note: Includes two Internal Combustion Engines 

as well as Traction Motor)

03**** Internal Combustion Engine (Includes PCM) Major Differences V6 including air induction 

and filtration

Major Differences I4 including air induction 

and filtration

031700 Traction Motor (Includes Traction Motor Controller) 6 Speed Automatic Hybrid CVT

Unique Auxiliary cooling system for Motor 

Electronics Cooling (MECS)

040000 Suspension System

040100 Front Suspension Subsystem Front Road Spring, Front Suspension Links / Arms 

Upper and Lower

Strut, Spring & Stabilizer bar part number 

differences

Strut, Spring & Stabilizer bar part number 

differences

040200 Rear Suspension Subsystem Rear Road Spring, Rear Suspension Links/Arms 

Upper & Lower Spring part number differences Spring part number differences

040300 Shock Absorber Subsystem Requires Additional Disassembly Requires Additional Disassembly

040400 Wheels And Tires Subsystem Same Same

040500 Suspension Load Leveling Control 

Subsystem N/A N/A

040600 Rear Suspension Modules Requires Additional Disassembly Requires Additional Disassembly

040700 Front Suspension Modules Requires Additional Disassembly Requires Additional Disassembly

050000 Driveline System

050100 Driveshaft Subsystem Requires Additional Disassembly Requires Additional Disassembly

050200 Rear Drive Housed Axle Subsystem N/A N/A

050300 Front Drive Housed Axle Subsystem Requires Additional Disassembly Requires Additional Disassembly

050400 Front Drive Half-Shafts Subsystem Requires Additional Disassembly Requires Additional Disassembly

050500 Rear Drive Half-Shafts Subsystem N/A N/A

050700 4WD Driveline Control Subsystem (Assume Front Wheel Drive) N/A N/A

060000 Brake System (Note: Includes Generator as part of Regenerative 

Brake System)

060301 Front Rotor and Shield Front Rotors and Calipers Requires Additional Disassembly Requires Additional Disassembly

060401 Rear Rotor and Shield Rear Rotors and Calipers Requires Additional Disassembly Requires Additional Disassembly

060500 Parking Brake and Actuation Subsystem Requires Additional Disassembly Requires Additional Disassembly

060600 Brake Actuation Subsystem Master Cylinder Ass'y, Actuation, Hoses, Tubes Reservoir has packaging differences Reservoir has packaging differences

060700 Power Brake Subsystem (for Hydraulic) Booster Requires Additional Disassembly Requires Additional Disassembly

060800 Power Brake Subsystem (for Air) N/A N/A

060900 Brake Controls Subsystem ABS Module located right front ABS Module relocated for Packaging

061000 Auxiliary Brake Subsystem Regenerative Brake (Generator) Requires Additional Disassembly Requires Additional Disassembly

070000 Transmission System

6 Speed Automatic Hybrid CVT

090000 Exhaust System Downsize??

090100 Acoustical Control Components 

Subsystem Dual Muffler Single muffler

Major Differences

Major Differences

Major Differences V6 vs. I4 Hybrid

Minor Differences observed based on part numbers additional investigation 

required

Additional investigation required

Minor differences noted based on packaging constraints. Additional investigation 

required
090200 Exhaust Gas Treatment Components 

Subsystem dual close couple cats single close couple cat

090500 Exhaust Modules Dual outlet single outlet

100000 Fuel System Downsize??

100100 Fuel Tank And Lines Subsystem Part Number Differences Part Number Differences

E85 Compliant Not E85 Compliant

110000 Steering System

Due to additional vehicle weight and potential 

distribution differences, there may be some steering 

system changes.

110100 Manual Steering Gear Subsystem Requires Additional Disassembly Requires Additional Disassembly

110200 Power Steering Subsystem Requires Additional Disassembly Requires Additional Disassembly

110400 Steering Column Subsystem Requires Additional Disassembly Requires Additional Disassembly

110500 Steering Column Switches Subsystem Requires Additional Disassembly Requires Additional Disassembly

110600 Steering Wheel Subsystem Requires Additional Disassembly Requires Additional Disassembly

120000 Climate Control System Not sure how cabin air system is used to cool battery?

120100 Air Handling/Body Ventilation Subsystem Requires Additional Disassembly Requires Additional Disassembly

120200 Heating/Defrosting Subsystem Requires Additional Disassembly Requires Additional Disassembly

120300 Refrigeration/Air Conditioning Subsystem Compressor is belt driven, Hose/tube is 

insulated

Compressor is electrically driven, 

Hose/tube is NOT insulated

120400 Controls Subsystem Requires Additional Disassembly Requires Additional Disassembly

130000 Information, Gauge and Warning Device System

130100 Instrument Cluster Subsystem Major Differences Major Differences

130600 Horn Subsystem Requires Additional Disassembly Would assume to be common

130700 Clock/Timekeeping Subsystem Requires Additional Disassembly Would assume to be common

131300 Parking or Reversing Aid Subsystem N/A N/A

140000 Electrical Power Supply System (Note: Includes Battery & Management System, Inverter 

Subsystem)

140100 Service Battery Subsystem 500 CA, Location Differences 390 CA, Location Differences

140200 Generator/Alternator and Regulator 

Subsystem (HEV Gen. included in regenerative braking) N/A Unique to Hybrid Only

140300 High Voltage Traction Battery Subsystem Includes Battery & Battery Management System N/A Unique to Hybrid Only

140500 Voltage Converter / Inverter Subsystem N/A Unique to Hybrid Only

140600 Fuel Cell Subsystem N/A Unique to Hybrid Only

140700 Fuel Processing Subsystem N/A Unique to Hybrid Only

140800 Energy Management Module Subsystem Generator Controller. N/A Unique to Hybrid Only

150000 In-Vehicle Entertainment System

150100 Receiver and Audio Media Subsystem N/A N/A

150200 Antenna Subsystem N/A N/A

150300 Speaker Subsystem N/A N/A

150500 Radio Noise Suppression Subsystem N/A Requires Additional Investigation

150700 Video Subsystem N/A N/A

170000 Lighting System

170100 Front Lighting Subsystem Same Same

170200 Interior Lighting Subsystem Requires Additional Investigation Requires Additional Investigation

170300 Rear Lighting Subsystem Same Same

Differences require further investigation

Requires further investigation, Differences appear to be minor

Requires Additional Investigation

Major differences in Compressor, Minor in tube/hose routing & Insulating

Major Differences in driver displays

Major Differences associated with Hybrid Drive

Additional Suppression may be associated with Hybrid drive
170400 Lighting - Special Mechanisms 

Subsystem Requires Additional Investigation Requires Additional Investigation

170500 Lighting Switches Subsystem Requires Additional Investigation Requires Additional Investigation

180000 Electrical Distribution and Electronic Control System (Note: Includes HEV Controllers)

180100 Electrical Wiring and Circuit Protection 

Subsystem I/P Wiring, Engine Wiring, etc one large fuse/power distribution box

one medium fuse/power distribution box & 

a second relay box

180200 Flashers Subsystem N/A N/A

180300 Electrical Distribution Switches 

Subsystem

Hidden switches and sensors (i.e., brake by wire 

sensors) Requires Additional Investigation Requires Additional Investigation

180400 Miscellaneous Electrical Devices 

Subsystem Requires Additional Investigation Requires Additional Investigation

Hood switch mounting locations are 

different

Hood switch mounting locations are 

different

180600 Traction And High Voltage Power 

Distribution Subsystem High Voltage Power Distribution Box & Wiring N/A

Unique to Hybrid Only, adds an additional 

thru hole in floor pan

180700 Power Electric Center (PEC) Subsystem Requires Additional Investigation Requires Additional Investigation

180800 EV, Hybrid, Fuel Cell Subsystem Control modules for PT (ICE, TM, etc), Vehicle System 

Controller (VSC) N/A Unique to Hybrid Only

190000 Electronic Features System (Note: Includes Vehicle Emergency Message 

Subsystem)

190100 Anti-Theft Warning Subsystem N/A N/A

190200 Remote Convenience Subsystem N/A N/A

190300 Intelligent Cruise Control Subsystem Requires Additional Investigation Requires Additional Investigation

190400 Side & Rear Vision Subsystem N/A N/A

190500 Vehicle Emergency Message (VEMS) 

Subsystem Requires Additional Investigation Requires Additional Investigation

190600 Voice Control Subsystem N/A N/A

190700 Vehicle Route Guidance/Navigation 

Subsystem N/A N/A

190800 Cellular Phone Subsystem N/A N/A

191000 Multiple Function Electronic Control 

Subsystem Requires Additional Investigation Requires Additional Investigation

191100 Electronic Compass Subsystem N/A N/A

191200 Keyless Vehicle Subsystem N/A N/A

191300 Television Subsystem N/A N/A

191700 Consumer Electronics Wireless Interface 

Subsystem N/A N/A

Major Differences associated with Hybrid Drive

Requires Additional Investigation
System Subsystem # Subsystem Name Subsystem Description Ford Fusion V6 Gas Engine Ford Fusion I4 Hybrid

010000 Body Systems (Note: Includes Instrument Panel/P, Body HVAC, 

and Seating Subsystems)

020000 Frame And Mounting System

030000 Engine System (Note: Includes two Internal Combustion Engines 

as well as Traction Motor)

040000 Suspension System

050000 Driveline System

060000 Brake System (Note: Includes Generator as part of Regenerative 

Brake System)

070000 Transmission System

090000 Exhaust System Downsize??

100000 Fuel System Downsize??

110000 Steering System

Due to additional vehicle weight and potential 

distribution differences, there may be some steering 

system changes.

120000 Climate Control System Not sure how cabin air system is used to cool battery?

130000 Information, Gauge and Warning Device System

140000 Electrical Power Supply System (Note: Includes Battery & Management System, Inverter 

Subsystem)

150000 In-Vehicle Entertainment System

170000 Lighting System

180000 Electrical Distribution and Electronic Control System (Note: Includes HEV Controllers)

190000 Electronic Features System (Note: Includes Vehicle Emergency Message 

Subsystem)

Additional investigation required

Minor differences noted based on packaging constraints. Additional 

investigation required

Major Differences 6 Speed Auto vs CVT

Major Differences - Y pipe for V eng & dual outlet vs. single outlet I4 exhaust 

Major Differences in rear seats, and in trunk trim, some minor differences related 

to packaging constraints

Minor Differences in mounts additional investigation required

Major Differences V6 vs. I4 Hybrid

Minor Differences observed based on part numbers additional investigation 

required

Requires Additional Investigation

Major Differences associated with Hybrid Drive

Additional Suppression may be associated with Hybrid drive

Requires Additional Investigation

Major Differences associated with Hybrid Drive

E85 and Fuel Tank Differences require further investigation

Requires further investigation, Differences appear to be minor

Major differences in Compressor, Minor in tube/hose routing & Insulating

Major Differences in driver displays
Major Area Subsytem

Engine Compartment Beauty Cover

Engine Compartment Engine

Engine Compartment Transmission

Engine Compartment Engine Battery

Engine Compartment Brake Master Cylinder Reservoir

Engine Compartment AC tubes/hoses

Engine Compartment Washer Fill

Engine Compartment ABS Module

Engine Compartment Radiator Close Out

Engine Compartment Fuse Box

Engine Compartment Air Induction

Engine Compartment Cooling System

Engine Compartment Cooling System

Engine Compartment Fuel

Suspension Front Suspension

Suspension Front Suspension

Suspension Front Suspension

Suspension Rear Suspension

Exhaust Exhaust

Fuel Fuel Tank

Heat - AC Heat & AC Systems

Heat - AC AC Compressor

Interior Rear Seat Cushion

Interior Insulation

Interior Trunk

Interior Rear Seat Backs

Interior Trunk

Interior IP

Exterior Floor

Exterior

Ford Fusion Comparison Differences
V6 - 6spd Automatic transmission

No Engine Cover

V6: 3.0L

6 Speed Automatic

500 CA Battery

Typical

Insulated

Typical

right front corner

Typical

Much Larger than hybrid

Each is unique 

Additional teardown required to determine

E85 Compatible

Strut Part Number Differences

Coil Spring Part Number Differences

Sway bar differences - packaging

Coil Spring Part Number Differences

Dual Outlet - Y pipe up front with dual close 

coupled cats

part number differences

Additional teardown required to determine

Belt Driven

Standard foam rear seat cushion

Trunk load floor/carpet typical

Rear Seats fold down with cable release

Unique Trunk Side Close Outs

Unique Instrument Cluster/Pannel

The Exterior and the Body sheet metal appear to be common with minor differences 

Ford Fusion Comparison Differences
I4 Hybrid Drive

Engine Cover

I4: 2.5L 

Hybrid - CVT

390 CA Battery

Reduced size for packaging

Not Insulated

Relocated for packaging

Relocated for packaging

Modified to facilitate hood switch

secodary relay box in front area

Each is unique 

Additional teardown required to determine

Unique Auxilary cooling system for Motor Electronics 

Cooling (MECS)

Not designed for E85

Strut Part Number Differences

Coil Spring Part Number Differences

Sway bar differences - packaging

Coil Spring Part Number Differences

Single Outlet - single coupled cat

part number differences

Additional teardown required to determine

Electrically Driven

Rear seat cushion contains integral ducting for cooling 

battery pack

Additional insulation under rear seat

Same as V6 except reduced length

rear seats fold down - no cable release or trim cover

Unique Trunk Side Close Outs

Unique Instrument Cluster/Pannel

Through hole in floor pan for cables

etal appear to be common with minor differences