🔧 Fusion - Engine Oil & Oil Filter Replacement

This job replaces the old engine oil and oil filter so your Fusion’s 2.0L plug-in hybrid gasoline engine stays protected and lubricated. The Energi system can start the gasoline engine automatically, so the key safety step is making sure the vehicle is fully OFF before working underneath it.

Difficulty Level: Beginner | Estimated Time: 45-75 minutes

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⚠️ Safety & Precautions

• ⚠️ Make sure the vehicle is fully OFF and the key/fob is away from the vehicle before working underneath it.
• ⚠️ Do not work on any orange high-voltage cables or hybrid battery components; they are not involved in this oil change.
• ⚠️ Use jack stands if lifting the vehicle. Never rely on a floor jack alone.
• ⚠️ Engine oil can be hot. Let the engine cool until it is warm, not burning hot.
• ⚠️ Wear safety glasses and gloves to avoid oil contact with your eyes and skin.
• ⚠️ Battery disconnect is not required for this oil change.

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🔧 Required Tools

You'll need the following tools for this repair:

• 15mm socket
• 3/8-inch drive ratchet
• 3/8-inch drive torque wrench
• Oil filter wrench, 74mm 14-flute cap style
• 3/8-inch drive extension, 6-inch
• Oil drain pan, 8-quart minimum
• Funnel
• Floor jack, rated 2-ton minimum
• Jack stands, rated 2-ton minimum
• Wheel chocks
• Nitrile gloves
• Safety glasses
• Shop towels

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Engine oil, SAE 5W-20 full synthetic or synthetic blend meeting Ford WSS-M2C945-A/B1 - Qty: 4.5 quarts
• Engine oil filter - Qty: 1
• Engine oil drain plug gasket or replacement drain plug, if equipped or damaged - Qty: 1

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📋 Before You Begin

• 🅿️ Park your Fusion on level ground and set the parking brake.
• 🛞 Place wheel chocks behind the rear wheels before lifting the front.
• 🌡️ If possible, run the gasoline engine briefly so the oil flows easier, then shut the vehicle fully OFF.
• 🔑 Move the key/fob away from the vehicle so the hybrid system cannot wake up while you work.
• 📘 A torque wrench tightens a bolt to a measured force so it is not too loose or too tight.
• 📘 A cap-style oil filter wrench fits over the end of the filter like a socket.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Position And Secure The Vehicle

• Use wheel chocks behind the rear wheels.
• Use a floor jack to lift the front of your Fusion at the front jacking point.
• Place jack stands under the approved front support points, then lower the vehicle gently onto the stands.
• Give the vehicle a light shake by hand to confirm it is stable before going underneath.

Step 2: Open The Hood And Remove The Oil Fill Cap

• Use your hand to remove the engine oil fill cap on top of the engine.
• Pull the dipstick slightly upward with your hand.
• This helps the old oil drain more smoothly.
• Keep the cap where it cannot fall.

Step 3: Place The Drain Pan

• Put on nitrile gloves and safety glasses.
• Slide the oil drain pan under the engine oil drain plug.
• The drain plug is at the bottom of the engine oil pan.

Step 4: Drain The Old Engine Oil

• Use a 15mm socket and 3/8-inch drive ratchet to loosen the drain plug.
• Finish removing the drain plug by hand while keeping inward pressure on it to reduce splashing.
• Let the oil drain until it slows to a drip.
• Inspect the drain plug and gasket. Replace the gasket or plug if the sealing surface is damaged.

Step 5: Reinstall The Drain Plug

• Wipe the drain plug area clean with shop towels.
• Thread the drain plug in by hand first to avoid cross-threading.
• Use a 15mm socket and 3/8-inch drive torque wrench to tighten the drain plug.
• Torque to 27 Nm (20 ft-lbs)

Step 6: Remove The Old Oil Filter

• Move the oil drain pan under the oil filter area.
• Use the 74mm 14-flute cap-style oil filter wrench, 6-inch extension, and 3/8-inch drive ratchet to loosen the oil filter.
• Spin the filter off by hand once it is loose.
• Keep the open end facing upward as much as possible to reduce spills.
• Check that the old rubber gasket came off with the old filter.
• A stuck old gasket can cause a big leak.

Step 7: Install The New Oil Filter

• Use a clean gloved finger to apply a thin film of fresh 5W-20 engine oil to the new filter gasket.
• Thread the new oil filter on by hand until the gasket touches the engine mounting surface.
• Use your hand to tighten the filter an additional 3/4 turn after gasket contact.
• If using a torque wrench with the cap-style filter wrench, torque to 16 Nm (12 ft-lbs).
• Do not overtighten the filter.

Step 8: Add New Engine Oil

• Use a funnel in the oil fill opening.
• Pour in about 4.0 quarts of SAE 5W-20 engine oil first.
• Wait one minute, then use the dipstick to check the level.
• Add oil slowly until the dipstick reads near the full mark.
• Total capacity with filter replacement is approximately 4.5 quarts.
• Reinstall the oil fill cap by hand.

Step 9: Start And Leak-Check

• Remove all tools from the engine bay.
• Start your Fusion in a mode that runs the gasoline engine if possible.
• Let it run for 30-60 seconds.
• Use safety glasses and look underneath for leaks at the drain plug and oil filter.
• Shut the vehicle fully OFF.

Step 10: Final Oil Level Check

• Wait 5 minutes so the oil can drain back into the oil pan.
• Use shop towels to wipe the dipstick clean.
• Insert the dipstick fully, remove it again, and read the level.
• Add small amounts through the funnel if needed.
• Do not overfill past the full mark.

Step 11: Lower The Vehicle

• Use the floor jack to raise the front of the vehicle slightly off the jack stands.
• Remove the jack stands by hand.
• Use the floor jack to lower your Fusion slowly to the ground.
• Remove the wheel chocks.

Step 12: Reset The Oil Life Monitor

• Turn the ignition ON without pressing the brake pedal, or power the vehicle ON without driving.
• Use the steering wheel buttons to open Settings > Vehicle > Oil Life Reset.
• Press and hold OK until the display shows the oil life has reset to 100%.
• If your cluster menu is different, use Settings > Vehicle Settings > Oil Life Reset.

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✅ After Repair

• ✅ Check under the vehicle again after your first short drive.
• ✅ Recheck the dipstick level the next morning on level ground.
• ✅ Dispose of used oil and the old filter at a recycling center or auto parts store that accepts used oil.
• ✅ Write down the mileage and date so you know when the next service is due.

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💰 DIY vs Shop Cost

Shop Cost: $80-$150 (parts + labor)

DIY Cost: $35-$70 (parts only)

You Save: $45-$80 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.4-0.7 hours.

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🎯 Ready to get started?

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