What 1,455 owners told NHTSA about the 2016 Ford Fusion Energi

The contact owns a 2016 Ford Fusion. The contact stated that while stopped in traffic or at a red traffic light on several occasions, on the way to an independent mechanic, the vehicle stalled. The contact stated that the vehicle was able to restart on each occasion after several attempts. The check engine warning light was illuminated. The contact stated that upon taking the vehicle to the independent mechanic and turning the vehicle off, the vehicle failed to restart. The mechanic diagnosed that the unknown sensor parts needed to be replaced. The vehicle was repaired, but the failure reoccurred a few months later. The vehicle was taken to the same independent mechanic on three occasions, where a tune-up was completed, and unknown parts were replaced; however, the failure persisted. The vehicle was taken to a dealer, where it was diagnosed with coolant intrusion into the cylinder due to a crack in the engine block. The dealer determined that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 70,000.

NHTSA ODI 11678494

The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle briefly shook violently, prompting the contact to discontinue driving the vehicle. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, who determined that there was coolant intrusion into various cylinders resulting in damages to the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. After investigating the failure, the contact related the failure to Customer Satisfaction Program: 21N12. The manufacturer was notified of the failure, a case was opened, and the contact was referred to the NHTSA Hotline for assistance. The failure mileage was 99,900.

NHTSA ODI 11673635

The contact owns a 2016 Ford Fusion. The contact stated that while driving at various speeds, an abnormal knocking sound was coming from the vehicle. The contact's husband changed the spark plugs; however, the failure persisted. The failure persisted, and the check engine warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed with coolant intrusion into the cylinder, resulting in engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. Several dealers were notified of the failure; however, each dealer informed the contact that there were no recalls related to the VIN. The manufacturer was made aware of the failure and provided a case number. The contact was referred to the NHTSA Hotline for further assistance. The failure mileage was approximately 117,000.

NHTSA ODI 11668195

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning illuminated, and the message to change spark plug #2 was displayed. The contact stated that whenever the vehicle was started, there was white smoke coming from the exhaust. The vehicle was taken to another independent mechanic, where it was diagnosed with coolant intrusion in cylinder #2, causing engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The contact stated that weeks before the failure, the vehicle was taken to an independent mechanic, who diagnosed the vehicle and determined that the solenoid and ignition coils needed to be replaced. The vehicle was repaired. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance. The approximate failure mileage was approximately 120,000.

NHTSA ODI 11664310

The contact 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 with coolant intrusion into the cylinders, causing engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The dealer was not contacted. The vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure, and a case was opened. The contact was referred to the NHTSA Hotline for further assistance. The failure mileage was approximately 87,000.

NHTSA ODI 11660626

The contact owns a 2016 Ford Fusion. The contact stated that while the vehicle was parked, the vehicle was shuddering abnormally. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed that there was an internal coolant intrusion into the cylinders and that the engine needed to be replaced. The independent mechanic made the contact aware of an unknown NHTSA Campaign Number; however, the VIN was not included. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline to report the failure. The failure mileage was approximately 115,385.

NHTSA ODI 11658956

The contact owns a 2016 Ford Fusion. The contact stated that while the vehicle was turned on, the contact attempted to change the spark plug; however, the spark plug was stuck. The vehicle was towed to the dealer, where it was determined that there was a hairline fracture in the engine, and there was coolant intrusion into the engine, and the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 100,000.

NHTSA ODI 11657244

The contact owns a 2016 Ford Fusion. The contact stated while driving 30 MPH, an abnormal sound was coming from the engine. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic, where it was diagnosed and determined that there was coolant intrusion into cylinder #2, causing engine failure. 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 referred the contact to the NHSTA Hotline for assistance. The approximate failure mileage was 117,000.

NHTSA ODI 11651895

The contact owns a 2016 Ford Fusion. The contact stated that upon starting the vehicle, there was heavy white smoke coming from the exhaust pipe with the check engine warning light illuminated. The vehicle was taken to an independent mechanic, where a code reader retrieved information for a defect with the EVAP system. The EVAP system was replaced by another independent mechanic; however, the check engine warning light returned several months after the repair. The vehicle was taken to another independent mechanic, where it was discovered that coolant was leaking into the spark plugs. The contact was informed that the engine needed to be replaced. The manufacturer was notified of the failure and the contact was informed that there were no recalls on the vehicle. The manufacturer referred the contact to the NHTSA Hotline to report the failure. The vehicle was not repaired. The failure mileage was approximately 124,000.

NHTSA ODI 11650161

The contact owns a 2016 Ford Fusion. The contact stated while driving at various speeds, the engine overheated. Additionally, the contact stated that the vehicle was experiencing excessive coolant consumption. The vehicle was taken to the dealer, where it was diagnosed with coolant intrusion into the engine. The dealer informed the contact that it was a known failure, and that the failure had occurred due to the design of the engine block. The dealer determined that the engine needed to be replaced. The vehicle was not repaired. The contact related the failure to TSB Number: 22-2322. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 149,000.

NHTSA ODI 11641662

The contact owns a 2016 Ford Fusion. The contact stated that while starting the vehicle, there was white exhaust smoke coming from the exhaust pipe while inspecting the vehicle. The vehicle was taken to the dealer but was not diagnosed or repaired. The contact related the failure to Ford Customer Satisfaction Program: 21N12 (Short Block Replacement After Coolant Intrusion); however, the vehicle was not included in the Ford Customer Satisfaction program. The manufacturer was made aware of the failure. The failure mileage was 131,000.

NHTSA ODI 11635326

The contact owns a 2016 Ford Fusion. The contact stated that while operating the vehicle the engine RPMs would sporadically increase and decrease between 500 and 2,000 RPM and the vehicle would not properly accelerate when pressing the accelerator pedal. Also, the check engine light began to intermittently blink on and off. The vehicle was taken to the local mechanic who diagnosed that the engine coolant was present inside engine cylinder number two. The contact was advised that the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure but no assistance was offered. The local dealer was not contacted. The failure mileage was 111,000.

NHTSA ODI 11634784

The contact owns a 2016 Ford Fusion. The contact stated while driving at undisclosed speeds, the engine was misfiring, causing the vehicle to stall occasionally. No warning lights were illuminated. The contact became aware that the coolant level was abnormally low. The contact stated that the vehicle was scheduled to be towed to be diagnosed. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 82,700.

NHTSA ODI 11633865

The contact owns a 2016 Ford Fusion. The contact stated that while operating the vehicle, the check engine warning light remained illuminated, and the vehicle experienced rough starts and failed to properly accelerate. The contact self-diagnosed a cylinder misfire in the engine and replaced the spark plugs and ignition coils, but the failure persisted. The vehicle was later taken to the local mechanic who diagnosed that coolant was present inside the engine and advised the contact that the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure, but no assistance was offered. The contact was informed that the vehicle was not covered under an Extended Warranty for the failure. The failure mileage was 75,380.

NHTSA ODI 11630276

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the contact noticed that the engine was overheating, and the vehicle started to shake with the coolant warning light illuminated. The vehicle was restarted; however, the failure recurred. The dealer was contacted. The vehicle was not diagnosed or repaired. The contact was referred to the manufacturer for further assistance. The manufacturer was made aware of the failure and referred the contact to the NHSTA Hotline for assistance The failure mileage was approximately 112,000.

NHTSA ODI 11627203

The contact's daughter owns a 2016 Ford Fusion. The contact stated there was heavy white smoke coming from the exhaust pipe after starting the vehicle. The check engine warning light was illuminated. The vehicle was taken to the dealer and was diagnosed with engine failure due to coolant intrusion into the engine. The vehicle was repaired by the dealer. The manufacturer was notified of the failure and the contact was provided a case number. The contact was referred to the NHTSA Hotline for assistance. The failure mileage was approximately 106,000.

NHTSA ODI 11625437

The contact owns a 2016 Ford Fusion. While the contact’s son was operating the vehicle, the vehicle failed to accelerate as needed, with white smoke coming from the exhaust. The contact stated that the vehicle started shaking before the vehicle stalled. The vehicle was restarted and later driven to the local dealer, who diagnosed the vehicle and determined that there was coolant inside the engine cylinders. The contact was informed that the engine needed to be replaced. The vehicle was not yet repaired. The manufacturer was notified of the failure, but no assistance was provided. The failure mileage was 77,000.

NHTSA ODI 11624903

The contact owns a 2016 Ford Fusion. The contact stated while parked with the engine running the vehicle's "overheating" warning chimed and he observed that the heat gauge was in the "red zone." The contact turned the vehicle off, checked under the hood, and observed that the coolant reservoir was low. The contact filled the reservoir, however the failure reoccurred. The contact refilled the reservoir and checked for any coolant leaks under the vehicle and did not observe any puddles. The contact took the vehicle to an independent mechanic who diagnosed the vehicle and determined that coolant had intruded into the cylinders. The mechanic referred the contact to a dealer. The contact called a dealer and was told that he needed to contact the manufacturer. The manufacturer advised the contact that there was a TSB Number: 19-2346 but that he would have to pay for the repair. The vehicle was not repaired. The failure mileage was approximately 112,000.

NHTSA ODI 11620533

The contact's mother owns a 2016 Ford Fusion. The contact stated while her mother was driving at an undisclosed speed, the check engine warning light was illuminated. Additionally, the driver noticed a strong coolant odor. The vehicle was taken to an independent mechanic, where the contact was informed that there was a coolant intrusion into the oil reservoir. The contact was referred to the dealer for assistance. The vehicle was then taken to the dealer, but the vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 132,646.

NHTSA ODI 11620555

The contact's mother owns a 2016 Ford Fusion. The contact stated that while his mother was driving 45 MPH, the vehicle inadvertently decelerated to 5 MPH. The low coolant warning light was illuminated. The contact's mother pulled over and parked the vehicle. The vehicle was towed to the dealer, where it was diagnosed with coolant intrusion into the cylinders, and it was determined that the engine needed to be replaced. The vehicle was not repaired. The contact related the failure to Technical Service Bulletin: 21-2269 (Low Coolant, White Exhaust Smoke, And/or Illuminated MIL); however, the vehicle was not covered under the TSB. The manufacturer was made aware of the failure and a case was opened. The failure mileage was approximately 82,000.

NHTSA ODI 11619060

The contact owns a 2016 Ford Fusion. The contact stated while the vehicle was parked, the contact noticed that there was white smoke coming from the exhaust pipe and the check engine warning light was illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the spark plugs, and the ignition coils needed to be replaced. The vehicle was repaired; however, the failure occurred. The vehicle was taken to the independent mechanic and the contact was informed that the spark plugs and ignition coils needed to be replaced again. The vehicle was repaired; however, the failure reoccurred. The vehicle was taken to the independent mechanic where it was diagnosed that there was coolant intrusion into the engine and the engine needed to be replaced. A dealer was contacted and made the contact aware of an undisclosed recall; however, the VIN was not included. The vehicle was not repaired. The manufacturer was contacted and confirmed that the VIN was not included in the recall. The contact was referred to the NHTSA Hotline to report the failure. The failure mileage was approximately 165,000.

NHTSA ODI 11618682

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, there was smoke coming from the exhaust, and the vehicle lost motive power with the check engine and the engine coolant over temperature warning lights illuminated. The vehicle was towed to the dealer where it was diagnosed that there was coolant leaking into the engine, causing engine failure. 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 referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 121,761.

NHTSA ODI 11616369

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle inadvertently lost motive power. The contact was able to pull to the shoulder of the roadway, where the vehicle was restarted. However, after traveling a short distance, the vehicle lost motive power and failed to restart. No warning lights were illuminated. The vehicle was towed to an independent mechanic, who diagnosed a failure with the turbo. The vehicle was not repaired. The vehicle was taken to another independent mechanic, who determined that the turbo only required cleaning. The vehicle was not repaired. The vehicle was then taken to the dealer, who diagnosed a failure with the torque converter resulting in damages to the transmission. The contact was informed that the transmission needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and referred the contact to the NHTSA Hotline for assistance. The failure mileage was 110,000.

NHTSA ODI 11614890

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed, the vehicle stalled with the check engine warning light illuminated. The vehicle was restarted; however, the failure recurred. The vehicle was taken to an independent mechanic. The vehicle was diagnosed with coolant leaking into the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The vehicle was taken to the dealer and was diagnosed with the same failure. 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 referred the contact to the NHSTA Hotline for assistance. The failure mileage was approximately 147,000.

NHTSA ODI 11610247

The contact owns a 2016 Ford Fusion. The contact stated while driving 45 MPH, the shifted into LIMP Mode, with the engine coolant temperature warning light illuminated. The vehicle was able to be restarted; however, the failure recurred. The vehicle was taken to the dealer where the vehicle was diagnosed with engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 135,000.

NHTSA ODI 11608259