2016 FORD FUSION Engine Problems

Head gasket and block cracked and caused coolant to leak into cylinder and caused misfiring and over heating and check engine light with smoke coming out of tailpipes

The engine failed completely needing full replacement @ 110,270 miles. Technical Service Bulletin 22-2322, super ceding TSB 22-2134 (attached file ford gave me) Coolant leak into cylinder 2 due to engine defect. I was getting on the highway when the car suddenly started overheating, the warning light did come on. This was roughly around [XXX], I do not recall the exact date. Then suddenly everything went back to normal. Engine temp was perfect within a second. When I got home, I checked the coolant, and it was very low. So, I replaced the coolant. The next time I started the car it barely started, and White smoke poured out the exhaust. I then parked it in the garage, and it sat. After researching what the issue was. I knew I couldn't afford a $10,000 bill. Recently I had to take a loan and brought the car in to be inspected...

My 2016 Ford Fusion with 90,000 miles has a coolant intrusion problem. This has caused my car to shake, smell, run terribly, hesitate while driving in traffic, almost losing power and now not starting. The first time I had trouble starting my car I took it to the Ford dealer that has always worked on my cars and was told I have a coolant intrusion issue. They said coolant leaked into a cylinder due to a design issue and there is no recall at this time. My service engine light would go on and off. When we called the dealer about the light going on and then not coming back on for weeks at a time they said when the light goes back on and stays on to call them and they would have a look. This started about 6 months ago. The light would only light up a couple...

Was driving and vehicle started to shake and lose speed. Check engine light came on. Checked and said misfire in cylinder 3. Took to mechanic and said coolant leaked into engine, plugs were corroded and heads cracked. Total engine replacement needed. Ford does not have recall for this year or model even though it's a widely known issue. I still have a loan on this car that I now can't drive as I don't have an extra $5000 to pay for an engine and my extended warranty won't cover it.

Antifreeze is leaking into the engine and now the engine needs replaced. Ford is aware of faulty 2.0 turbo engines but has not recalled it. I bought an extended warranty and they won't cover it. I have been a Ford guy my whole life but that will change because Ford knows about the issue but won't do anything about it.

The engine cooling failed inside the block on cylinder #2. The cooling system is not operable and resulted in blue smoke under acceleration. The car is no longer under warranty and only has 65K miles on it and is otherwise in good working order. I am told the whole engine needs to be replaced.

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was towed to the dealer. The vehicle was diagnosed with head gasket and block engine failures. The dealer stated that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 120,000.

My 2016 Ford Fusion check engine light came on and started blowing white smoke out of the exhaust. I had it towed to the Ford dealership and they told me that my entire engine needs to be replaced because of a coolant link on the engine. They said my car overheated and had no coolant. I know my engine had coolant and there was no sign of a leak. There was no notification of the car overheating. After researching on the internet there is a known part that cause this problem. Ford is aware and they aren't fixing it. My car could have caught on fire with no fault of my own. I can't afford to pay $10,000 for a new engine. This is an extreme financial hardship for me.

Coolant leaking into cylinder, overheating, headgasket

First noted engine acting sluggish about a week prior to 2-13-24 oil change at Firestone. They suggested it may be the fuel injection system needing to be cleaned, which they performed on 2-14-24. Engine continued to run sluggish and was in fact worse than before, engine light came on 2-21-24 so Firestone replaced fuel injector that day. Error codes were reading misfire in cylinder 2, the engine was still full of carbon and other buildup so they thought there was still residue and thoroughly cleaned everything again after replacing fuel injector. On 2-22-24 I refueled after work and car would not start. AAA was dispatched to tow vehicle and I notified Firestone it would be brought in, fortunately after about 15 minutes I was able to start it and drive it to Firestone, engine light immediately came on. They looked at it first thing on 2-23-24 and engine started up...

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, he observed plumes of white smoke emanating from the exhaust, after which the vehicle lost motive power. The contact was able to pull to the shoulder of the roadway, where the vehicle failed to restart. The check engine warning light was illuminated. The vehicle was not taken to the dealer or an independent mechanic. The vehicle was not repaired. After investigating the failure, the contact related the failure to Technical Service Bulletin: 22-2322. The manufacturer was notified of the failure, and a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 175,000.

My vehicle has been maintained by the dealer and myself for the 87800 miles that have been put on it. I purchased the vehicle in August of 2016 brand new with 34 miles on it. The motor has a manufacturing defect, the block was built in the same plant (Hermosillo, HERMOSILLO, MEXICO)that other Ecoboost motors were built in that were recalled for the coolant leaking into cylinders via a "fix" which was cutting a channel between the cylinders on the deck of the long block between the cylinder walls, this compromised the integrity of the seal between the cylinder head and head gasket. This allowed coolant to leak into cylinder 4 of my vehicle. Ford has known about the issue for the last several years and continues to make these motors. The dealer I purchased the vehicle from wants $14,000 to replace the motor with a new long block but...

I have this car with a coolanat leak into the Cylinder causing a misfire resulting in fuel/oil in cylinder and white smoke coming from the exhaust. i keep on having codes pop up and my cabin smells like burnt oil my kids are smelling this on a daily basis its bad for their health i know Ford knows about this problem. if my car catches fire because of the oil problem whos responsible, I've changed out spark plugs. coils. fuel injectors. all sensors. an nothing seems to work. when i changed my oil it looks like oil is flooding my motor an covering my entire engine an leaking everywhere its also a road hazard

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to the dealer, where it was diagnosed with a coolant leak in cylinder #4 and it was determined that the engine needed to be replaced for the second time. The vehicle was not repaired. The contact stated that the engine had previously been replaced; however, the failure recurred. The manufacturer was made aware of the failure. The failure mileage was approximately 72,000.

The contact owns a 2016 Ford Fusion. The contact stated that when the vehicle was started, the contact noticed that the engine was misfiring. The check engine warning light was illuminated. The contact replaced coil pack however, a month later the failure reoccurred. The contact noticed that the coolant reservoir was empty but there were no signs of a leak. The vehicle was not diagnosed or repaired by an independent mechanic or dealer. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 138,000.

The contact owns a 2016 Ford Fusion. The contact stated that the check engine warning light illuminated while starting the vehicle. The contact also stated that the vehicle hesitated while depressing the accelerator pedal while driving at various speeds. The vehicle was taken to an independent mechanic where several speed sensors were replaced. The contact then stated that while driving in stop-and-go traffic, the vehicle stalled with white smoke coming from under the hood. There was no warning light illuminated. The contact drove the vehicle to a parking lot where it was later towed to an independent mechanic. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was approximately 103,000.

The contact owns a 2016 Ford Fusion. The contact stated that the vehicle hesitated while depressing the accelerator pedal and was shaking abnormally while idling with the check engine warning light illuminated. Additionally, the contact stated that the temperature gauge indicated that the vehicle was hot with white smoke coming from the exhaust pipe. The vehicle was initially taken to an independent mechanic who diagnosed the vehicle with a defective spark plug. The spark plug was replaced; however, the failure persisted. The vehicle was then taken to a dealer, and it was discovered that there was coolant intrusion into an engine cylinder. The vehicle was diagnosed with engine failure. The manufacturer was notified of the failure but offered no assistance. The vehicle had yet to be repaired. The failure mileage was approximately 130,000.

After doing research I have found that I am not the only one experiencing this issue,but I have a 2016 ford fusion 1.5 ecoboost engine and I am having problems with my cylinder leaking. I have to constantly refill coolant and the only option to fix this issue is to replace the motor

COOLANT LEVEL DROPPING WITHOUT ANY VISIBLE EXTERNAL LEAKS.-CREATING OVERHEATING WITH NO VISIBLE LEAK SEEING. WHICH HAS CREATED TO CHANGE WATER PUMP / CHANGE COILS DUE TO MISFIRES AND LOSS OF ENGINE POWER.OVERHEATING AND CONSTANT ADDING OF WATER/COOOLANT.

The contact owns a 2016 Ford Fusion. The contact stated that the check engine warning light was illuminated. Additionally, the contact stated while driving 60 MPH, the check engine warning light illuminated with a message indicating that the engine was overheating. The vehicle lost motive power. The contact was able to veer to the side of the road. The vehicle was able to restart. The vehicle was towed to an unknown dealer, who informed the contact that the coolant reservoir was empty. The contact added coolant to the vehicle and drove to the residence. The vehicle was then taken to the local dealer, where it was diagnosed with coolant intrusion in the engine, causing the spark plugs to be corroded, and that cylinder #4 was misfiring. The dealer determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and informed...

Driving on highway and car had serious misfire stalling the engine. No lights or warnings prior. Upon inspection number 1 cylinder has near zero compression.

The contact owns a 2016 Ford Fusion. The contact stated while driving at 55 MPH, the accelerator pedal was depressed however, the vehicle failed to properly respond. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic and the spark plugs were replaced; however, the failure persisted. The vehicle was then taken to the dealer and the contact was informed that the engine was damaged due to coolant intrusion. The vehicle was repaired. The manufacturer was contacted and stated that due to the age and the mileage of the vehicle there would not be a reimbursement for the repair. The approximate failure mileage was 165,000.

Check engine light on. Engine coolant over temp Took vehicle to dealer, the verdict was; Removed all spark plugs & using bore scope detected coolant intrusion in cylinder 3. Needs long block assy.

Head gasket blew, coolant in cylinder 4, needs a new engine. Well know problem that can cause extreme hazards.

The contact owns a 2016 Ford Fusion. The contact stated that when the vehicle was started, the contact heard a tapping sound coming from the engine compartment. The vehicle was taken to a dealer where it was diagnosed that the flex wheel needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 180,000.

A couple days before scheduled tune-up, noticed that 2016 Ford Fusion(Ecoboost), began to drive differently. Exactly one day prior to service appt. the check engine icon appeared. Long and short, dealership reached out after me leaving car to explain that my 7 yr. old vehicle with regular maintenance, just over 100,000 miles, and no prior issues could not receive a regular maintenance tune-up due to spark plug(s) being wet from leaking coolant and an engine replacement being the only option of repair. Although, I was told at the time and read that this habitual issue was common in my make and model, there were no recalls in place to rectify the issue. Safety at risk based on other Googled reviews and articles with the same known issue with consequences ranging from low coolant to possible total engine shut down or fire. It was those reviews with similar diagnosis and recommendations...

I brought my ford fusion 2016 SE with around 84,000miles on it, into a local dealership for recalls I needed done, my car was running completely fine before that. Ford did a multi point inspection and I passed for everything besides tires and brakes which was expected! Not even 12 hours after getting my car back, my check engine light turned on.. I was so confused on how that was happening. I contacted ford again and they told me my coolant pressure was low but that wasn’t even stated in my multi point inspection. Anyways I had to go to work the next day and my car completely stops in the middle of a main road & my car wouldn’t accelerate. The person behind me almost slammed into my back end. I have never had a complaint about my car, I love my fusion. But after further research this is...

In July took vehicle to Ford service center for car throwing “engine coolant about temperature” warning. They told me there was a crack in engine caused by RECALL 23E03. They gave me invoice stating so but it’s a LIE because that recall has nothing to do with the engine. I have paperwork to prove they stated so and they were asking for +$10k for repair and labor. I declined the work. They also confirmed coolant intrusion. They told me I had to tow my car out of there as it was not operational but when I arrived I was able to drive it off. In august vehicle began to throw warning for “engine coolant above temperature” again.” When this would happen temp gauge would go to MAX, but as soon as warning went away, temp immediately dropped to medium temp.I took it to another mechanic. Warning light turned onwhen going...

Cylinder 2 misfire, coolant leak - engine

While driving on Interstate 75 from Fort Lauderdale to Tampa, the check engine light began to flash and the car began to shake violently. I had to bring it into a Ford dealer in Naples FL. It turns out that there is a known coolant intrusion issue into the engine and a class action lawsuit has been filed against Ford. There are a number of technical service bulletins as well however they are not issuing a recall.

Date of first incident was Nov 19, 2023. I was driving home from taking my elderly mother to the doctor and my engine just shut off. I had plenty of gas, my oil and transmission had been changed, no warning lights came on my dash prior to the engine stopping. The only message I had on my car said the car is not in park. No one can seem to find out why. It has done this at a moderate rate of speed (45mph). My steering wheel locked and I can't steer the car giving me the option to get to a safe place on the road. I have to hit another vehicle or hit a pole. I have good insurance but I don't want to use it to fix body damage. I can't afford that with a 300 dollar car payment. My break sensor error light will come on...

The contact owns a 2016 Ford Fusion. The contact stated that while his son was driving at an undisclosed speed, the vehicle experienced rough driving with the check engine warning light illuminated. The contact stated that he had previously replaced the spark plugs and coils due to a cylinder #3 misfire. The vehicle was taken to the dealer, where it was diagnosed with coolant intrusion into the engine. The contact was informed that the engine long block needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to file a complaint with the NHTSA Hotline. The failure mileage was approximately 88,000.

The contact owns a 2016 Ford Fusion. The contact stated while driving approximately 15 MPH, there was dark smoke coming from the exhaust pipe. The check engine warning light was illuminated. The vehicle was taken to a dealer where it was diagnosed that the engine needed to be replaced due to coolant leaking into the engine block. The contact stated believed that the vehicle was associated with an unknown recall. The manufacturer was notified of the failure. The failure mileage was 132,000.

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The contact stated that the engine was idling rough with white smoke coming from the exhaust. The vehicle was towed to the dealer to be diagnosed. The contact was made aware of coolant intrusion into the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and advised the contact to report the failure to the NHTSA Hotline. The failure mileage was approximately 158,000.

I currently have a 2016 Ford Fusion SE with the 1.5L engine. Upon starting the car, the check engine light came on and idled roughly. After scanning the codes for the check engine light, it was determined that it was experiencing a cylinder 3 misfire. I took the car to the dealership and upon repair, they uncovered there was a coolant intrusion coming from the engine and either a "band-aid fix" was needed for $3,500 dollars or a full engine replacement for $8000+ dollars was needed. The dealership confirmed that they have seen this being a known issue for this type of vehicle/engine but there was no relief for the repair. After moving forward with the $3,500 repair to replace the head gasket, it was determined that even then the car was inoperable, and I was left without a vehicle and a bill to pay.

The 2.0 liter Ecoboost engine developed a cracked block at the seven year, 94,000 mile point. The cracked block leaked coolant into the number 2 cylinder thereby causing the check engine light to illuminate. The cracked block necessitated a full engine replacement. The cracked block could have caused a catastrophic engine failure while in operation, putting the driver and other drivers on the road at risk. Research indicates this is a known problem with this engine.

Engine started running very rough, hesitating and surging. OBD-2 computer codes indicate cylinder misfires. Engine is very hard to start. Coolant level is rapidly dropping, and engine overheating frequently. White smoke seen from exhaust. Acceleration is very slow and merging into moving traffic is difficult and dangerous. Reading that engine fires have been reported. Refer to Ford Technical Service Bulletin 22-2229 regarding coolant intrusion into cylinders. Took to local repair shop and they diagnosed leaking coolant reservoir and failed fuel injector. These were replaced at a cost of $2,000. See uploaded invoice.

Car was having difficulty starting and occasionally overheating. Check engine light came on and read that 1st ignition coil and spark plug needed to be replaced. The repair was done and the problem persisted. Car continued to overheat and lost coolant rapidly. Brought the car back to the shop and was told that the coolant was emptying into the engine and the engine needed to be replaced.

The contact owns a 2016 Ford Fusion. The contact stated that while driving at various speeds, the vehicle stalled. The driver was able to restart the vehicle. There were no warning lights illuminated. The vehicle was taken to an independent mechanic, who stated that the failure was due to the throttle. The vehicle was repaired, but the failure recurred. The vehicle was taken to another independent mechanic, who replaced the coil valve, but the failure recurred. The vehicle was taken to the local dealer, where it was diagnosed that the module needed to be replaced. The vehicle was repaired, but the failure persisted. The vehicle was taken back to the same local dealer but was not diagnosed or repaired. The manufacturer was not contacted. The failure mileage was approximately 65,550.

Coolant leak into engine causing over heating 24/7, damaging and leaking into combustion chamber , spark plugs had to be replaced , engine needs another replacement after I had replaced it the first week I got it with the vehicle’s warranty, engine is at risk for engine fire and failure. Transmission shifter cable replacement, became detached and damaged, car was stuck in reverse twice and had to be towed to mechanic . Current Recall on breaks because of possible fluid leak for ford fusions , at risk for crash. Engine currently is shakey when you first start it up.

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the check engine warning light illuminated. The contact stated that the following day there was white smoke coming from the exhaust. The contact stated that the vehicle was taken to an independent mechanic. The contact stated the independent mechanic replaced the spark plugs and replaced the number two fuel injector. The failure reoccurred. The vehicle was taken back to the independent mechanic. The vehicle was then diagnosed with fuel intrusion into the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was approximately 122,000.

I was driving to this morning and the check engine light started blinking and the car started to shake i looked it up and it said the engine was misfiring and what not. But it would shake when idling and driving. I had a loss of power and had to pull of the highway to avoid danger.

Vehicle stalled multiple times at traffic lights in heavy traffic. Took vehicle to dealership and was told that engine coolant is leaking into the engine and the entire engine would have to be replaced at a cost of over $10,000. Called Ford Customer Service and was told that even though it's a known problem which is being reported by many customers they will not replace the engine or help with the cost.

one day my car randomly showed a sign that my engine was over heating. So I pulled over and was able to Uber to an auto part get more coolant for the car. Since that day forward I had to replenish the coolant at least every two weeks when I went to get a diagnostic they told me I had an internal coolant leak and that I was going to need a new engine and then also my head gasket was blown. I only had the car for a little under two years. As I did reasearch I realized this is a major problem among ford fusions and other ford cars in general. I believe ford knows all about this issue and the engine design being faulty.

The engine failed ( I was told by Lithia Springs Ford Dealership that coolant was leaking into the engine and now I have to replaced the whole engine). The guy "Richard" at the dealership immediately pointed out that coolant could be leaking into the engine when I told him that fluid was found on one of the spark plugs. He said that Ford Fusion with the size engine 1.5 have been having this problem alot. It is available for inspection. My safety and the safety of every other vehicle on the road was put at risk as I was driving and then my check engine light started blinking. My vehicle started vibrating hard and fast causing me to impede the flow of traffic on the interstate and almost get rear ended why driving in the far left lane (the fast lane). I immediately got off the interstate and slowly drove...

TSB 19-2172 Check Engine light lit due to a rough startup condition. ODB codes indicated the vehicle had a misfire of cylinder three. Replaced 4 spark plugs and the 3rd cylinder coil pack. 2 days later the car began to overheat to low coolant levels. "Engine Coolant Over Temperature" Added 3/4 gal of coolant and took to dealership. Dealership confirmed engine was compromised due to coolant intrusion after performing the pressure test.

From 2014-2019 Ford Fusion eco boost engines are faulty. Coolant leaks into the engine. Causing the car to consistently overheat and seize up.

The contact owns a 2016 Ford Fusion. The contact stated while driving approximately 65 MPH, the check engine and the power train warning lights illuminated, and the vehicle suddenly stalled. The vehicle was towed to the residence and was later diagnosed by an independent mechanic. The independent mechanic determined that there was coolant intrusion into the engine, causing a misfire in cylinder #1. The vehicle was not repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 71,000.

I have a 2016 Ford Fusion SE Ecoboost wth 1.5 engine. In December 2021, while driving a block from my home, the engine overheated and I pulled over to find no coolant. There has been no coolant leaking under my car. Coolant was added that day, but has continually needed to be refilled. My check engine light had been coming on stating the sensor 2 ignition cable was bad, but we had replaced it along with spark plugs, but it kept coming up as a bad sensor and we confirmed it wasn't a defect part, it always showed sensor 2 as the problem. I took the car to my mechanic in June 2023 and he found that the fuel injector under that sensor wasn't being fed fuel continually, but skipping. He replaced the fuel injector and discovered the coolant leak was in the engine. I paid for a new gasket,...

The contact owns a 2016 Ford Fusion. The contact stated while driving approximately 25-28 MPH, the check engine warning light illuminated. The vehicle was taken to the dealer who determined that coolant was leaking into the engine. The dealer diagnosed that the engine needed to be replaced due to a misfire in cylinder #2 and #3. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure and confirmed that the VIN was not under recall. The contact was referred to the NHTSA Hotline for assistance. The approximate failure mileage was 60,000.