2016 Ford Fusion Engine Problems

The engine experienced a sudden failure that caused the vehicle to become completely inoperable. Prior to the failure, the vehicle exhibited intermittent hesitation, rough idling, and loss of power during acceleration. These symptoms began several weeks before the complete failure. No warning lamps were illuminated at first, but shortly before the breakdown, the vehicle displayed a check engine light and a “Service Engine Soon” message. While driving, the vehicle abruptly lost power and became unsafe to operate. I was forced to pull over immediately, which created a safety risk to myself and other drivers due to the sudden deceleration and inability to maintain speed in traffic. The vehicle would not restart afterward. A repair facility has confirmed that the engine has suffered a major internal failure and requires replacement. The estimated cost of repair starts upwards of $5,000. The vehicle is currently non‑drivable and remains available for inspection. The issue has been reproduced and confirmed by an independent service center. The vehicle has not yet been inspected by the manufacturer, police, or insurance representatives. However, I have found multiple similar complaints from other owners reporting the same type of powertrain failure, suggesting a potential pattern or defect affecting safety.

NHTSA ID

11752956

Incident

May 15, 2026

Engine reached high temperature on July 2 2016 the results of which required the replacement of the radiator. Apparently there is a class action regarding coolant system issues for my vehicles 2.0L engine. The radiator failure may be the result of this issue. Engine overheated

NHTSA ID

11748924

Incident

Jul 2, 2026

The contact owns a 2016 Ford Fusion. The contact stated that while driving the vehicle at an undisclosed speed, the vehicle felt as though it were going to shut off unexpectedly. The check engine warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that the spark plugs needed to be replaced. The contact stated that after the spark plugs were replaced, one of the cylinders was misfiring. The spark plugs were replaced a second time, but the failure persisted. The vehicle was taken to another independent mechanic, where it was diagnosed that coolant intrusion into the engine had resulted in engine failure, and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 130,000.

NHTSA ID

11748561

Incident

Jul 6, 2026

Mileage

130,000 mi

On April 25, 2024, my car broke down as I was driving. There were no warning lights leading up to it, and then all of a sudden, the check engine light started flashing, my temperature gauge spiked, and I was forced to pull over as the car barely responded to the gas pedal. When I got out, there was smoke coming out from under the hood, and just moving the car to get it towed better made the engine shudder and screech. At that time, the mechanic replaced the water pump, which appeared to solve that issue. But after that, between April and November 2024, my check engine light came on no less than 5 times. Each time, I took my car to the mechanic and they identified and fixed the code to the best of their abilities, but a few weeks later, the light would be back on again. They said the car might have an internal coolant leak and needed a new spark plug and ignition coil. Even after they replaced the spark plug and the ignition coil, I would also occasionally hear screeching sounds as I drove, or-- the longer this went on-- the car would shudder any time the engine was running. Finally, my mechanic told me that the internal coolant leak was something only the dealership could fix, so I took it to Ford, who evaluated the car and found an internal leak in cylinder 2. The only way to fix it would be to replace the entire engine, which I could not afford. The car has been sitting undriven ever since. If I'd been on the highway or driving at a faster speed when the engine suddenly cut out, I could've been in an accident. The only warning for the cylinder issue was the continuous check engine light and the shuddering of the engine, and the same issue was confirmed by an independent mechanic (AutoExpress in Doylestown and the Ford Dealership). There are numerous results on a Google search regarding Ford EcoBoost engine coolant intrusion which is the exact issue I'm having but Ford has not recalled the 2016 Fusion nor offered any solution to this dangerous manufacturing defect

NHTSA ID

11748292

Incident

Apr 25, 2024

My Ford Fusion with the Ecoboost 2.0L 4-cyl engine has the design flaw that has the issue with a coolant to leak into the combustion chamber. Mine is in cylinder #2. The local dealer quoted $10K to replace the engine because it has the design flaw. I need this repaired because I need it to get to work. my 2016 fusion should also be covered by the recall.

NHTSA ID

11747953

Incident

Jan 2, 2026

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the message "No Coolant" was displayed on the instrument panel, and there was smoke coming from outside of the vehicle. The vehicle was taken to an independent mechanic, where it was diagnosed with a blown head gasket. The contact was informed that the engine needed to be replaced. The independent mechanic made the contact aware of an undisclosed recall; however, the VIN was not included in a recall related to the failure. The vehicle was repaired. The manufacturer was notified of the failure. The contact stated that while reversing at an undisclosed speed, the rearview camera image was inverted and the rear passenger’s side of the vehicle crashed into an unoccupied vehicle. No warning lights were illuminated. The failure had occurred on several occasions. A police report was not filed. The contact received notification of NHTSA Campaign Number: 25V695000 (Back Over Prevention); however, the part to do the recall repair was not yet available. A local dealer was not contacted. The contact stated that the manufacturer had exceeded a reasonable amount of time for the recall repair. The manufacturer was made aware of the issue. The failure mileage was approximately 99,000.

NHTSA ID

11745909

Incident

Nov 23, 2025

Mileage

99,000 mi

For the past year, I have been dealing with a recurring check engine light on my Ford Fusion related to Diagnostic Trouble Code P0301 – Cylinder 1 Misfire. Despite multiple repair attempts by qualified mechanics, the issue continues to return, leaving me with mounting repair bills, lost confidence in my vehicle, and serious concerns about its reliability and safety. Every time the check engine light has appeared, I have taken my vehicle in for diagnosis and repair. Each time, I was assured the problem had been fixed. However, the repair would only last anywhere from a week to a month before the exact same code would return. I have now experienced this issue on August 8 2025, January 9 2026, April 20 2026, May 19 2026, and June 1 2026. I have paid to address the same problem, along with related repairs, five separate times. Even more concerning, my vehicle has broken down and left me stranded on the side of the road three out of those five occurrences. No vehicle owner should have to repeatedly face the same unresolved issue after spending significant money on repairs and maintenance. After conducting extensive research, I discovered that I am far from alone. I have found numerous reports from other Ford Fusion owners experiencing the exact same Cylinder 1 misfire issue, many of whom have also been unable to find a permanent solution despite repeated repairs. This appears to be a widespread problem affecting many customers, not an isolated incident. As a Ford customer, I expected a dependable vehicle that I could trust to safely get me where I need to go. Instead, I have spent the last year dealing with recurring failures, unexpected expenses, and the constant fear of being stranded again. When so many owners are reporting the same defect with no lasting repair available, it raises a serious question: Why has this issue not been investigated for a recall or other manufacturer supported corrective action? I urge Ford to thoroughly investigate this recurring issue.

NHTSA ID

11742902

Incident

Aug 8, 2025

The entire engine/motor

NHTSA ID

11740520

Incident

May 4, 2026

There is a problem with the purge valve causing my vehicle to rough idle and even cut off on me in the middle of traffic and even on the interstate. This issue is going on with a plethora of people with the same year make and model as me yet no recall has been issued. When I put gas in the car it won’t start for some time. If I’m not constantly pressing the accelerator the car will turn off by itself

NHTSA ID

11738455

Incident

May 4, 2026

The contact owns a 2016 Ford Fusion. The contact stated that while driving at various speeds engine had overheated causing the vehicle to stall. The vehicle was taken to the local mechanic who was unable the determine the exact cause of the failure. The contact was informed of the manufacturer extend coverage regarding the engine coolant inside the engine cylinders. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure but no assistance was offered. The failure mileage was 175,000.

NHTSA ID

11735837

Incident

Apr 1, 2023

Mileage

175,000 mi

CAR IS OVER HEATING AND ENGINE LIGHT ON. SAME ISSUES AS THE 2017 FORD FUSIONS RECALL BUT I WAS TOLD THE FIRE RISK FROM ENGINE COOLANT LEAKS AND ENGINE BLOCK HEATER FAILING DOES NOT COVER MY YEAR EVEN THOUGH THE ISSUES ARE COMPLETLY THE SAME.

NHTSA ID

11733085

Incident

Mar 30, 2026

The contact owns a 2016 Ford Fusion. While driving at an undisclosed speed, there was an abnormal knocking sound coming from underneath the hood. The vehicle was towed to a dealer to be diagnosed, and metal shavings were found inside the engine in cylinders #1 and #4. Additionally, oil was found on top of the pistons in cylinders #2 and #3. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was 125,763.

NHTSA ID

11731227

Incident

Feb 1, 2026

Mileage

125,763 mi

I called way scarff ford to have the safety recalls taken care. Got my appointment, stopped the car off in the morning. They kept the car for 3 days and after the 3rd day they said everything is good to go. Go there in Auburn WA couldn't find my car. Took 4 people or including myself. Then it took another half hour to 45 min to find my car. Go get in the vehicle and something doesn't seem right. Everything still felt the same. I look under the hood and find that the the recalls for the cable bushing wasn't corrected so let led me to think that the other recalls were not completed. Befote calling ford corporate to have this issue taken care of we called [XXX] in enumclaw to have this taken care of. Since the car was at way scarff my car started to act funny. Lean idle, really rough idle vibration with now a code P0299 which is the underboost. I do not think they hooked the hoses up correctly. So now my car is acting really funny. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11729819

Incident

Feb 23, 2026

The plastic part on the transmission melted. I had to get my transmission rebuilt. This has been a problem for many Ford vehicles with this engine type because who makes a transmission out of plastic!?

NHTSA ID

11728532

Incident

Jun 10, 2025

I took my car in to diagnose low coolant and white exhaust smoke on cold start. The technician said he "observed the presence of coolant inside the cylinder walls which can lead to "serious damage...corrosion...failure and wear and could seize up and told me to get a new engine or car. The vehicle component was inspected by an independent service center. No warning lights prior to failure. Other symptoms include low coolant, white exhaust smoke and runs rough condition especially on acceleration. Vehicle Condition Report (photos and videos) that shows you what our technicians saw today and includes any recommendations. The link to your report is: [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

NHTSA ID

11725614

Incident

Oct 16, 2025

My car is having a problem with the a coolant intrusion into the intake so coolant is leaking into the engine, this being said there was a recall for my car a while ago when I did not own the car and I believe it was never replaced or taken care of. When I went to the ford dealership they are saying that there is no recall for my car. The car misfired once which is one of the symptoms, I got my spark plugs replaced, my check engine light came on again for a different problem, I got my intake replaced it ran fine for 4 days and now I am back with the same problem 4 days later. Doing some research I believe that there is a cracked cylinder head or failing gasket. Ford did have a recall on my engine coolant intrusion but like I said prior they are saying there is no recall for my engine which is why I am confused about it. All of my engine problems are leading to this recall that was never fixed on my car or was looked over in my engine. Any help on this would be great thanks

NHTSA ID

11713158

Incident

Jan 1, 2026

The engine experienced a piston misfire that occurred internally, causing a fracture within the engine block. The resulting damage allows oil intrusion into the spark plug chamber. This constitutes a mandatory safety concern that requires immediate attention.

NHTSA ID

11712314

Incident

Aug 20, 2024

The contact owns a 2016 Ford Fusion. The contact stated that the check engine warning light was illuminated. The vehicle was taken to the dealer, where it was diagnosed with coolant intrusion into the cylinders. The dealer determined that the engine needed to be replaced. The vehicle was not repaired and was taken back to the residence. The contact stated that the vehicle had failed to start. The message "See Owner's Manual" was displayed. The contact related the failure to the Customer Satisfaction Program: 21N12 (Short Block Replacement After Coolant Intrusion). The manufacturer was not notified of the failure. The failure mileage was approximately 100,000.

NHTSA ID

11710747

Incident

Nov 13, 2025

Mileage

100,000 mi

The contact owns a 2016 Ford Fusion. The contact received notification of NHTSA Campaign Number: 25V695000 (Back Over Prevention). While driving at an undisclosed speed, the vehicle started running rough. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic who retrieved DTC: P0302 (Misfire in Cylinder #2). The vehicle was taken to another independent mechanic, who retrieved the same code and informed the contact that cylinder #2 ignition coil and spark plug needed to be replaced. The vehicle was repaired. While driving, there was white smoke coming from the tailpipe, but the vehicle was still running rough. The engine overheated, and the contact pulled over and added additional fluids to the engine. The vehicle was taken to the local dealer, where it was diagnosed with coolant intrusion, and the engine needed to be replaced. The vehicle was not repaired. The contact obtained an extended warranty, but the claim was denied due to not meeting the mileage requirements. While driving at 35 MPH, the vehicle stalled. The vehicle was towed to the residence. The manufacturer was not notified of the failure. The approximate failure mileage was 138,000.

NHTSA ID

11709586

Incident

Sep 6, 2025

Mileage

138,000 mi

My vehicle has the Ford EcoBoost 2.0 liter engine in it that has been recalled on thousands of vehicles. My car currently has the same issue which is a coolant intrusion that has been recognized and was a class action lawsuit against Ford for this issue. I have been advised by a local Ford dealership that my engine should be part of the recall and Ford should be replacing my engine. However, when I called Ford, they are advising there is nothing they can do, because there is no current recall for my vehicles VIN and so I am trying to reach out and see if there's anything that can be done before hiring an attorney, because as a single mother I cannot afford $12,000 out of my pocket with hopes that eventually Ford will do the recall properly and reimburse me as they have stated "could happen". This is a known issue this engine of mine has been looked at by three mechanics one being a Ford dealership to confirm that this engine was in fact warped from the factory which is causing my coolant to seep into the heads or whatever and I need the long block replacement that the original recall fell under which was somewhere around the 50,000 mark of these vehicles recalled. The engine is needing to be repaired and taken care of so I'm seeking direction on how to possibly get Ford to take care of this issue that I should not be having to deal with due to a manufacturing defect since leaving off the factory floor

NHTSA ID

11709310

Incident

Nov 24, 2025

The engine light intermittently went off and on for a few weeks. During that time, the car would surge and slow/loose power while driving it, which was distracting when in traffic. The dealership found that coolant had leaked into the engine block and we were informed the engine had to be replaced. I talked to 2 dealerships and they both said this was something they had seen a lot - and while the engine for the Ford Escape was recalled, the same engine was not recalled for the Ford Fusion.

NHTSA ID

11703880

Incident

Jul 30, 2024

The contact's daughter owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that there was coolant intrusion in cylinder #4. The mechanic informed the contact that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not informed of the failure. The failure mileage was approximately 92,000.

NHTSA ID

11701451

Incident

Nov 20, 2025

Mileage

92,000 mi

See attached document for complaint.

NHTSA ID

11699363

Incident

Oct 20, 2025

The contact owned a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, there was an abnormal sound coming from underneath the hood. No warning light was illuminated. The vehicle was taken to a local independent mechanic, where the engine gasket was replaced, and the vehicle was diagnosed with a warped engine block. The vehicle was repaired. In addition, the contact was informed that there was a coolant intrusion leak and an engine overheating failure. The local dealer was not contacted. The vehicle was not diagnosed or replaced. The manufacturer was made aware of the failure. The failure mileage was approximately 150,000.

NHTSA ID

11697557

Incident

Nov 5, 2025

Mileage

150,000 mi

The contact owns a 2016 Ford Fusion. The contact stated that the vehicle failed to immediately start, and the check engine warning light was displayed. The vehicle was towed to the local dealer, who diagnosed that the vehicle had experienced coolant intrusion into the cylinders. The vehicle was not repaired. The manufacturer was notified of the failure and informed the contact that the vehicle was covered under the Manufacturer's Extended coverage related to the failure. The failure mileage was 120,000.

NHTSA ID

11694711

Incident

Jan 21, 2025

Mileage

120,000 mi