NHTSA Complaint #11673109 — 2017 FORD FUSION

In July 2025, my 2017 Ford Fusion SE (EcoBoost engine) was diagnosed with coolant intrusion into cylinder #4 by Sunrise Ford in North Hollywood, CA. This is a known issue with the 1.5L and 2.0L EcoBoost engines and is addressed in Technical Service Bulletin (TSB) 19-2208. The vehicle had only 76,000 miles at the time and had been regularly serviced and well-maintained. Over the past 1–2 years, I received repeated warnings during oil changes that my coolant levels were unusually low, though no leaks were found. In July 2025, the check engine light (CEL) appeared. The vehicle exhibited rough idle at cold start, but otherwise drove normally. I immediately brought the car to the dealership, where they confirmed the problem through diagnostics and plug inspection. The dealership quoted me $11,000–$12,000 to replace the engine (long block). Ford Customer Relations (CRC) was contacted and denied financial assistance, citing the age of the vehicle. They also acknowledged this is a known issue and suggested I file a report with the NHTSA, which I am now doing. This engine failure presents a serious safety risk. The CEL appeared without warning during normal use. A driver unfamiliar with the signs of internal coolant loss could continue operating the vehicle, risking a sudden loss of engine power, stalling, or further engine damage while in motion. In my case, the failure occurred quietly and was only caught because I acted quickly. Had I ignored the CEL or rough idle, engine failure could have occurred at highway speed. The issue was confirmed and documented by a Ford dealer. I am no longer in possession of the vehicle, as I was forced to sell it at a loss due to the cost of repairs. The vehicle is no longer available for inspection, but all related documentation has been retained.