NHTSA Complaint #11606488 — 2018 FORD FUSION

Originally, the car had Cylinder 2 misfire followed by the engine overheating. No crash, thankfully. have had this car for approximately 2 years, and put less than 30,000 miles on it. I took the car to Kings Ford Services where they discovered the engine block had been miscast resulting in engine coolant to enter cylinders 2 and 4, thus killing the engine. Spoke with Eric Hutton, Service Advisor Kings Ford Inc, (513)-683-0220 ext. 219, who said he has seen this happen multiple times with Ford Fusions and that the 1.5L has been recalled, but not the 2.0L which my car has. Per Kings Ford Repair Receipt: "Inspected the engine base part number to confirm it I'd 206 then with the engine at normal operating temperature, pressurized the cooling system to 20 PSI FOR 5 hours and the pressure dropped more than 4 PSK. Removed the spark plugs, used a borescope and found coolant has entered the cylinders. Removed the engine and replaced the long block assembly using all of the approved Ford gasket removers, parts cleaners, shampoo and metal surface prep wipes to clean all related mating surfaces per the workshop service manual. Also replaced all other related seals, gaskets, and non reusable hardware and reinstalled all components Removed for repairs in the reverse order of removal. Evachated, pulled system into vacuum, and recharged thr air conditioning system to service the engine assembly." I called Beechmont Ford who filed a claim with my warranty, but the warranty refused to aid and gave many excuses that were not true to the problem such as "it was a gasket issue not an engine" despite Mr. Hutton telling them multiple times it was the engine. I found out later their excuses were just that as Ford Inc. said the warranty expired within a year of having the car. They also had heard of this happening before, as well. Ford Inc. who was willing to pay a portion of the bill, $5,000, despite it being a manufacturing issue. Car was fixed and returned to me on 08/01/2024.