Ford Fusion (2002 – 2012) Review

Ford Fusion (2002 – 2012) At A Glance

3/5

+Versatile interior. Easy to get in and out of. Reasonably sized load area with no lip. Four-star crash test rating, economical TDCI diesels.

-Rear hatch must be opened remotely. Not a looker. Patchy build quality. Doesn't handle as well as a Fiesta. Feels dated.

Insurance Groups are between 9–14
On average it achieves 91% of the official MPG figure

Ford Fusion (2002 – 2012) handling and engines

Fusions never really took off in the UK, despite their slightly higher driving position and their huge rear loadspace with flat low-loading sill. A peculiar omission is no grab handle over the front passenger seat, which isn't going to help the elderly and infirm make entry and exit. But for a small, tall car the Zetec S version handles decently enough. A bit better than a Mitsubishi Colt or the class-leading Honda Jazz, though no better than its stablemate Mazda 2. And the EU IV 92PS diesel gives it a decent combination of performance and economy just over the magic 120g/km CO2, without a DPF.

Engine MPG 0-62 CO2
1.4 44 mpg 14.0 s 154 g/km
1.4 Durashift 46 mpg 15.3 s 149 g/km
1.4 TDCi 63 mpg 16.1 s 120 g/km
1.6 37–43 mpg 11.1–13.1 s 157–179 g/km
1.6 TDCi 63 mpg 12.9 s 119 g/km

Real MPG average for the Ford Fusion (2002 – 2012)

RealMPG

Real MPG was created following thousands of readers telling us that their cars could not match the official figures.

Real MPG gives real world data from drivers like you to show how much fuel a vehicle really uses.

Average performance

91%

Real MPG

27–71 mpg

MPGs submitted

322

Ford Fusion (2002 – 2012) interior

Dimensions
Length 4013 mm
Width 1724 mm
Height 1512 mm
Wheelbase 2486 mm

Full specifications

You sit higher than the Fiesta, which makes it a bit easier to get in and out of.

The main benefit over the Fiesta is a flat folding rear seat, flat load deck and lipless, station wagon-like rear sill.

Ford Fusion (2002 – 2012) models and specs

Dimensions
Length 4013 mm
Width 1724 mm
Height 1512 mm
Wheelbase 2486 mm
Miscellaneous
Kerb Weight 1161–1175 kg
Boot Space 318–1109 L
Warranty 3 years
Servicing 12500 miles
Costs
List Price £11,995–£16,245
Insurance Groups 9–14
Road Tax Bands C–I
Official MPG 37.2–62.8 mpg
Euro NCAP Safety Ratings
Adult 4
Child -
Pedestrian 2
Overall -

On sale until March 2011

Hatchback
Version List Price MPG 0-62
Titanium 1.6 5dr £13,295 42.8 mpg 11.1 s
Zetec 1.4 5dr £12,295 43.5 mpg 14.0 s

On sale until March 2010

Hatchback
Version List Price MPG 0-62
Style+ 1.4 5dr £13,745 43.5 mpg 14.0 s
Style+ 1.4 Durashift EST 5dr £14,245 45.6 mpg 15.3 s
Style+ 1.4 TDCi 5dr £14,445 62.8 mpg 16.1 s
Titanium 1.6 TDCi 5dr £16,245 62.8 mpg 12.9 s
Zetec 1.4 TDCi 5dr £15,045 62.8 mpg 16.1 s
Zetec 1.6 5dr £14,945 42.8 mpg 11.1 s
Zetec 1.6 5dr Auto £14,945 37.2 mpg 13.1 s
Zetec 1.6 TDCi 5dr £15,645 62.8 mpg 12.9 s

On sale until May 2009

Hatchback
Version List Price MPG 0-62
Plus 1.4 5dr £13,795 43.5 mpg 14.0 s
Plus 1.4 Durashift EST 5dr £14,295 45.6 mpg 15.3 s
Plus 1.4 TDCi 5dr £14,495 62.8 mpg 16.1 s
Plus 1.6 5dr £14,395 42.8 mpg 11.1 s
Plus 1.6 5dr Auto £14,395 - -
Plus 1.6 TDCi 5dr £15,095 62.8 mpg 12.9 s
Style 1.4 5dr £11,995 43.5 mpg 14.0 s
Style 1.4 Durashift EST 5dr £12,495 45.6 mpg 15.3 s
Style 1.4 TDCi 5dr £12,695 62.8 mpg 16.1 s
Zetec 1.4 Durashift EST 5dr £13,695 45.6 mpg 15.3 s

Model History

August 2002

Fiesta-based 'Urban Activity Vehicle' on sale in UK from late 2002. Longer, wider and taller than the Fiesta, it is also more versatile. Interior very attractive with folding 60/40 split rear seat backs and a flat folding front passenger seat allowing the transportation of longer items. Rear load floor flush with hatchback sill.

Dimensions are: length 4,020 mm (13ft 2in); width 1,708mm (5 ft 7in); height: 1,503mm (4ft 11in). Luggage volume is 337 litres to the parcel shelf with the rear seats up. Three engines:

PSA sourced 1,399cc Duratorq TDCi aluminium block, common rail direct-injected diesel. Power output is 68ps at 4,000rpm with 160Nm (118 lb ft) torque at 1,750rpm. 0-60 is quoted at 15.1 seconds, top speed 99mph, Target Euro combined mpg 64.2 and CO2 emissions 119g/km (£85pa VED). This engine meets Euro III emissions limits.

1,388cc Duratec 16v petrol. Power output is 80ps at 5,700rpm with 124Nm (91 lb ft) torque at 3,500rpm. 0-60: 13.3 seconds, top speed 102mph, Target Euro combined mpg 43.5 and CO2 emissions 156g/km (£125pa VED). This engine meets Euro IV emissions limits.

1,596cc Duratec 16v petrol. Power output 100ps at 6,000rpm with 146Nm (108 lb ft) torque at 4,000rpm. 0-60: 10.5 seconds, top speed 111mph, Euro combined mpg 42.8 and CO2 emissions 158g/km (£125pa VED). This engine meets Euro IV emissions limits.

Standard equipment includes ABS with EBD, height adjustable drivers seat, twin dual-stage front airbags, five three-point seatbelts, decoupling pedals to protect the driver's feet in a severe impact, a passive anti-theft system, and a spare wheel stowed inside the boot rather than slung under it. Standard tyres 195/60R15 (as suggested in the original car by car posting) which is a reasonable compromise between handling and pot-hole protection. Side airbags, side curtain bags, perimeter alarm system and remote central locking are available either as standard or as extras. Durashift semi-automatic available from September 2003.

100PS 1.6 Durashift 4-speed full automatic from February 2004, list priced from £12,425, does 112mph and 0-60 in 11.4 seconds. Makes a lot of sense as an alternative to a Jazz CVT-7.

Four star NCAP crash safety rating.

01-10-2005: Facelifted for 2006 and on sale from November 2005. Range now included 1.6TDCI:1,560cc 16v Duratorq TDCI belt-cam diesel: 66kW (90PS) at 4,000 rpm; 204Nm (150 lb ft) torque at 1,750 rpm. 5-speed manual: 0-60 12.2 seconds; top speed 109 mph; combined mpg: 61.4; CO2 emissions: 122g/km.

For 2007, Fusion Pursuit and Pursuit Climate. 500 of these special editions from £10,995. Fusion Pursuit features a unique two-tone finish and a body styling kit with deep side mouldings extending from the front and rear bumpers and following the length of the car. Bespoke interior styling touches include a silver finish gear lever knob and optional interior styling pack. On the outside, alloy wheels, clear side indicators, rear spoiler, and front, rear lower and front upper skid plates. Fusion Pursuit Climate adds air conditioning, Quickclear windscreen and power heated mirrors. The Pursuit will be available in seven colours: colorado red, tonic, moondust silver, tango red, frozen white and verdigris and ocean blue, all matched with the lower body in black.

What to watch out for

01-01-0001:

I.4TDCIs suffered bout of broken fuel pipes in Spring 2004 and shortage of replacement parts. Not the big seller Ford had hoped. Percentage residual values lower than Fiesta. Water ingress to engine compartment causes damage to plugs, leads and coil pack.

'Whirring whine' from 1.4TDCI may be failing timing belt tensioner, which is a roller bearing device like the idler pulley, but with a reddish rubber/nylon damper. Gates cambelt kits include this part. Wise also to replace waterpump which it driven by the timing belt.

End of plastic dipstick of 1.6 TDCI engine can break and drop into sump requiring removal of sump to retrieve it.

ASM Module and gear actuators of 1.4 'Durashift' automated manual prone to failure after 4 - 5 years and replacement likely to cost £1,500.

Widespread problem with EAC (electronic accelerator control) failures on 1.25 and 1.4 petrol engines. Diagnostics identify a a throttle position sensor ratio error as the problem. May be due to corrosion in one of the connectors. Updated throttle bodies on back order in Novemmber 2009, not expected until January 2010.

Old Fiesta problem of the pins that hold the foot pedals in place may fall out, leaving the driver unable to brake or declutch. Apparent clutch failure may be due to nothing more than a spring washer on the shaft behind the clutch pedal coming loose. This pushes on. Ford dealers usually have the part in stock and it's a quick fix.

Front coil spring failure became extremely common by 2008/2009 on cars as young as 42 months old.

10-08-2011:

On 1.6TDCI, reports of oil feed pipe blockages to the turbo resulting in repeated failed turbos.

21-11-2013:

Injector failure on 47k mile 2009 Fusion 1.4TDCI first manifested by "juddering at 40mph". This is common on the 1.4TDCI in the Fusion, Mazda 2, Fiesta and Citroen C3. Cost £1,000 to replace.

25-01-2015:

Transmission fluid got past the seal and set off numerous can bus problems including poor starting and cutting out at junctions.

19-03-2018:

Report of injector failure on 2008 Ford Fusion diesel (not specified if 1.4TDCI or 1.6TDCI).