FordFusion Hybrid2016Overview/ford/fusion-hybrid/2016/base/

2016 Ford Fusion Hybrid

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2016 Fusion Hybrid.

Body PASSENGER CARTransmission Automatic (variable gear ratios)

The 2016 Ford Fusion Hybrid is a passenger‑car built on Ford’s midsize platform and powered by a hybrid drivetrain that relies on a 4.3‑quart oil capacity with 5W‑20 viscosity, paired with an automatic transmission featuring variable gear ratios and delivering an EPA rating of 43 mpg city, 39 mpg highway, and 41 mpg combined. While the model records a total of 1,655 owner complaints—most frequently centered on the engine—and has been subject to 13 recalls, its complaint tally sits well below the peak of 2,869 recorded in the 2011 model year and above the low of 791 in 2010, indicating a moderate reliability standing within the early‑generation Fusion Hybrid lineage. This positioning suggests that the 2016 iteration benefits from the refinements made after the highest‑complaint year, offering researchers a relatively stable reference point in the model’s overall reliability trajectory.

Model year20172016201520142013201220112010

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.3 qtOEM · verified
Engine oil type5W-20OEM · verified
EPA fuel economy43/39/41 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 90 · 500 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 90 · 500 CCAOEM · verified
Tire sizeP235/45R18OEM · verified

OE service part numbers OEM · verified

BatteryBAGM48H6760
Cabin air filterDG9Z19N619D

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic (variable gear ratios)

Dimensions & weight NHTSA vPIC

Overall length191.7 in
Overall width72.8 in
Overall height58.3 in
Wheelbase112.2 in
Curb weight3435 lb
Track (front / rear)62.6 / 62.6 in
Weight distribution (front / rear)59/41

Ratings & economy EPA / vPIC

EPA city / highway / combined43 / 39 / 41 mpg
DrivetrainFront-Wheel Drive
Passenger volume101 cu ft
Cargo volume16 cu ft
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.3 qt of 5W-20 engine oil, 80W-90 · GL-5 in the differential, DOT 4 brake fluid. Torque the oil drain plug to 18.0 ft-lbs. The firing order is 1-2-3-4. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission Fluid Capacity4.0-6.0
Brake FluidDOT 4
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity2.43 qt
Engine Coolant Capacity11.1 qt
Engine Coolant Capacity8.9 qt
Engine Coolant Capacity8.2 qt
Engine Coolant Capacity8.8 qt

Engine torques

Exhaust Manifold to Cylinder Head BoltsUniformly tighten fasteners. ft-lbs
Intake Manifold to Engine Bolts14.7
Exhaust Manifold to Cylinder Head Bolts1st step:
Intake Manifold to Engine Bolts13
Exhaust Manifold to Cylinder Head Bolts1st step:
Engine Oil Pan Drain Plug22.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs

Chassis torques

Driveshaft Flange to Transmission52.0 ft-lbs
Steering Track (Rod End) Bolts111.0 ft-lbs
Front Wheel HubInstall a new nut and torque to 148.0 ft-lbs
Rear Wheel HubInstall a new nut and torque to 148.0 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Cylinder Firing Order1-2-3-4
Spark Plug ManufacturerMotorcraft
Spark Plug Gap.028 in
Spark Plug Torque9 ft-lbs
Spark Plug ManufacturerMotorcraft
Spark Plug Gap.035 in
Spark Plug Torque11 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.25-1.50 lbs
Oil GroupPAG
Oil Type46
Oil Capacity4.90 oz
RefrigerantR134a
Refrigerant Capacity1.38 lbs
Oil Capacity4.40 oz

Service checks

Pressure Test18-20 psi
Thermostat Opening Temperature180-207 °F
Pressure Test14 psi
Thermostat Opening Temperature176-183 °F
Pressure Test14 psi
Thermostat Opening Temperature194-223 °F
Residual Pressure46-80 engine running psi
Regulated Fuel System Pressure (With Vacuum)46-80 engine running psi

Brakes

Brake Caliper Bolt to Carrier TorqueFront: 22; Rear: 21
Brake Caliper Carrier to Hub Bolt TorqueFront: 111; Rear: 66 /; Front: 111; Rear: 86
ABS Sensor Torque7.0
Minimum Pad ThicknessFront: 0.059; Rear: 0.059 in
Vented Rotor Minimum Thickness for ReplacementFront: 1.034; Rear: 0.374
Maximum Rotor Runout0.002

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

13.7 ft. lbs.3.7 ft. lbs
211.0 ft. lbs.11 ft. lbs
326.0 ft. lbs.26 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Intake Manifold to Engine Bolts — tightening sequence 1 stages

Prep 1st step: bolts 1, 2, 7: 1.4 ft/lbs · 2nd step: bolts 3, 4, 5, 6: 1.4 ft/lbs · 3rd step: bolts 1, 2: 13 ft/lbs · 4th step: bolts 3, 4, 5, 6: 7.4 ft/lbs · 5th step: bolts 1, 2: 13.2 ft/lbs · 6th step: bolts 7: 13.2 ft/lbs

7tighten bolts 3, 4, 5, 6 to 7.4 ft/lbs. See diagram IQ

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 10,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 10,000 miDrive Axle Assembly (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Engine Oil Pan (inspect) · Tire & Wheel Assembly (rotate)
Every 20,000 miAccessory Drive Belt (inspect) · Brake Line (inspect) · Brake Linings (inspect) · Brake Rotor (inspect) · CV Joint Boot (inspect) · Cabin Air Filter (replace)
Every 30,000 miEngine Air Filter Element (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill) · Hybrid Inverter (drain, flush & refill coolant)
At 100,000 miAccessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill) · Hybrid Inverter (drain, flush & refill coolant)
Every 100,000 miSpark Plugs (replace)
At 150,000 miDrive Belt (replace) · Transmission Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The federal record shows complaints for the Fusion Hybrid peaked at 2,869 in 2011 before declining to 1,861 in 2013, while recalls spiked sharply to 19 in 2013 from 6 the prior year. For the 2016 model year, the data reveals 58 crash complaints and 6 fire complaints, with the top complaint areas being Engine (315), Power Train (231), and Steering (118). Although the year-by-year table does not extend to 2016, the high concentration of engine and powertrain complaints suggests these systems remain a significant concern. Given the earlier recall surge and the persistence of powertrain-related issues in the target year, the 2016 Ford Fusion Hybrid carries a notable risk of mechanical problems. A buyer should proceed with caution and ensure a thorough inspection of the engine and transmission before purchase.

13
Open recalls
NHTSA campaigns
173
Service bulletins
Manufacturer communications
5
ODI investigations
Office of Defects Investigation
1,655
Owner complaints
58 involved a crash · 6 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Overall★★★★★
Frontal★★★★★
Side★★★★
Rollover★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 1,655 complaints on record, top 8 components.

Engine315
Power Train231
Steering118
Unknown Or Other114
Engine & Engine Cooling82
Back Over Prevention76
Electrical System52
Service Brakes46

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 13 campaigns on record for this vehicle.

19V632000Steering:Electric Power Assist SystemReported 29/08/2019

Ford Motor Company (Ford) is recalling certain 2013-2016 Ford Fusion and Lincoln MKZ, 2015-2016 Ford Edge, and 2016 Lincoln MKX vehicles originally sold, or currently registered in Connecticut, Delaware, the District of… Remedy: Ford will notify owners, and dealers will replace the steering gear motor bolts and apply a wax sealer. If any of the steering gear motor attachment bolts are broken or missing, a…

18V471000Power Train:Automatic Transmission:Lever And Linkage:Floor ShiftReported 16/07/2018

Ford Motor Company (Ford) is recalling certain 2013-2014 Ford Escape, and 2013-2016 Ford Fusion vehicles, equipped with six-speed automatic transmissions. The bushing that attaches the transmission shifter cable to the… Remedy: Ford will notify owners, and dealers will replace the shifter cable bushing, free of charge. The recall began September 20, 2018. Owners may contact Ford customer service at…

Technical service bulletins NHTSA · verified

Showing 5 of 173 bulletins on record with NHTSA.

BulletinDateComponentSummary
25E012026-05-01Power TrainCertain 2014-2016 Model Year Fusion Vehicles Equipped With 1.5L Engine - Powertrain…
SSM 546012026-02-23Electrical SystemFord and Lincoln vehicles equipped with wired keyless entry keypad systems and accessory…
25B612026-02-17Power TrainCertain 2013-2014 Model Year Escape and 2013-2016 Fusion Vehicles Equipped with a 6F35…
SSM 543662025-11-11Power TrainSome 2015-2021 Ford and Lincoln vehicles may exhibit an illuminated MIL with diagnostic…
25E012025-10-16Unknown Or OtherThe affected vehicles have an emissions control system that may not control tailpipe…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Fusion Hybrid. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2016 Fusion Hybrid take?

4.3 qt of 5W-20 meeting Ford specification WSS-M2C946-A or equivalent., per the factory manual.

Does the 2016 Fusion Hybrid have open recalls?

NHTSA lists 13 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Fusion Hybrid get?

EPA figures are 43 city / 39 highway / 41 combined mpg.