**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** 

**Ad ditional 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 SubsystemIncludes 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**

**Ad ditional 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 HVA C,**  **and Seating Subsystems) 020000** **Frame A nd 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)** 

### Ad**ditional investigation required Minor differences noted based on packaging constraints. A**  **dditional investigation required**  **Major Differences 6 Speed A uto 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 A**

**dditional Investigation Major Differences associated with Hybrid Drive**  **Ad ditional Suppression may be associated with Hybrid drive** 

**Requires A**

**dditional 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

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