Fusion emerged as a practical blend between a microvan and a five-door hatchback, tracing its roots to the fifth generation of the Ford Fiesta.
In terms of overall platform, the Ford Fusion shares a lineage with the Focus.
Assembly took place in Germany.
Restyling in 2006 brought a refreshed look and additional options, but did not introduce major structural changes.
Ford Fusion
Advantages:
- A straightforward, affordable and functional vehicle.
- Strong resistance to corrosion.
- Parts availability is reliable and plentiful.
- Ground clearance of 160 mm.
Post-styling design aimed to echo contemporary European fashion. Until 2005, the control knobs and switches carried a look reminiscent of earlier models.
Defects
- Robotized Durashift EST system.
- The trunk volume is modest at 337 liters.
engines
Duratec 1.4 (80 hp) and 1.6 (101 hp) engines have a reputation for reliability when properly maintained. In 2004 they were upgraded to Euro 4 and the throttle was changed from a cable to an electronic pedal.
Officially compatible with AI-92 gasoline, low quality fuel can quickly contaminate injectors and stress the fuel pump. AI-95 is still preferred for longevity.
The timing belt tends to wear before the factory promise of 150 thousand kilometers. To prevent belt failures, replacement around 80-100 thousand kilometers is advised. Ignition coils can fail, the alternator and water pump can have limited lifespans, and the intake manifold may experience plastic cracking.
For the 1.6 engine, a noted issue is the so-called double start, more common in wet, off-season conditions. The causes are not clearly identified, and it is not considered a severe defect. Regular air filter changes are recommended due to dust entering the engine through its design features.
Long-term data shows a 1.6 engine covering over 350 thousand kilometers and a 1.4 engine around 300 thousand kilometers, though acceleration and dynamic response may diminish with high mileage. Transition to gas can be somewhat cumbersome in both cases.
There is also a diesel Duratorq 1.4 (68 hp). It is exceptionally economical, but often finicky. The fuel system can be unreliable after high mileage, oil consumption rises after around 100 thousand kilometers, turbo wear is a concern, and the engine is generally robust up to about 250 thousand kilometers.
Transfer
The iB5 manual transmission, used with engines up to 1.8 liters, is dependable when treated with care and can reach high mileage. It is the same unit used in Fiestas and Focus models. The Durashift EST robotized unit fitted to the 1.4 engine uses a different clutch assembly and tends to exhibit jerky behavior from early on, with clutch wear around 60 thousand kilometers and a tendency toward electronic instability in traffic. It can theoretically last up to 250 thousand kilometers, but many owners test that claim sparingly.
The classic automatic transmission paired with the 1.6 engine is the Aisin AW80-41, a four-speed unit known for durability. With proper servicing, it typically does not show significant failures until well past 150 thousand kilometers and can reach around 300 thousand kilometers of service life.
operational ulcers
- The rear suspension shocks are a common weak point, sometimes needing replacement around 60 thousand kilometers, while the fronts last longer.
- The power steering pump tends to wear out around 60-80 thousand kilometers, and leaks in the steering system are not unusual. The steering wheel becomes quite firm and resilient over time.
- With the age of vehicles, wiring and electrical contacts may deteriorate, leading to electrical issues such as lights staying on, rear lock mechanisms failing, or wipers malfunctioning.
- Moisture intrusion into the cabin during wet weather is possible, and corrosion tends to affect the rear door more than other panels.
Euro NCAP rating in 2003: four stars
Recommended variant: Fusion 1.6 manual or automatic
Comparable options for the same budget include the Hyundai Solaris I, Kia Cee’d I, Nissan Tiida, and Opel Astra J
- Where to shop for a car that won’t be outbid? The answer unfolds here.
- Details about driving and ownership are available in the automotive press and forums in community hubs such as Odnoklassniki.