Purchased a 2016 Ford Fusion SE in July of 2021. First week I had the car the engine didnt crank/start. Took it to the dealership that I bought it from they sent me to their mechanic and was told nothing was wrong with it. Happened the third week of purchase went back to the dealership and was told to use my warranty and to take it to Ford. Took it to Ford and was told it had high resistance in my negative terminal in the battery. (First attempt August 2021) I was charged $400 to get the corrosion clean and put a coat on the terminal for protection. A week later my engine didnt start again. Had this problem for several weeks, one day the engine would start the next it wouldnt. I called Ford and was told to bring it back. (Second attempt Oct 2021) Ford told me they diagnosed the car and didnt find any codes to lead to the problem. Kept telling me the engine was starting when they had it but when i went to pick it up it wouldnt for me. (Third attempt Nov 2021) Went picked my car up from Ford on a Monday morning because it was ready and that they still didnt find anything wrong with it and it was starting up just fine. Leaving from work Monday night engine didnt start had to get it towed again to Ford Tuesday morning. I have called Ford headquarters to file a complaint. Do not purchase a Fusion they are terrible cars and Ford theirselves cant even find out what the issue is with the vehicle.

- Harvey, LA, USA

As with all other ford 2.0l Ecoboost engine. There apparently is a design flaw causing coolant intrusion into the cylinders. Which would require a new engine per Ford.

- Royse City, TX, USA

I have a 2016 Ford Fusion SE 2.0L. Got a P0303 code for a cylinder 3 misfire. The spark plugs and coils were replaced to no resolve. Still getting a P0303 code. Short term fuel trims are good so I dont think its an injector issue. The car began to over heat with out warning about a week after the P0303 code started presenting itself. This is dangerous as the vehicle could catch fire.

- Lubbock, TX, USA

Defect in engine design allowed coolant to leak into cylinder. There have been recalls on the 1.6L and 2.0L ecoboost engines but not the 1.5L for the same issue. I was advised that his could cause the engine to misfire and overheat possibly causing a fire. A quick search revealed several incremental TSB, 21-2269 is the latest, regarding this issue. This happened with approx 57,000 miles and 5 years 6 months on the car. The only fix was a complete engine swap.

- Lansing, KS, USA

Engine light came on after car overheated. Took car into local auto service center and was told I had a blown head gasket. I'm filling this complaint due to the numerous other complaints regarding this same issue on the same year make and model of my car. Had I not taken my car to the service center immediately, potential for safety issue could have been high and impacted myself, family, and other individuals driving near me.

- Nyssa, OR, USA

TSB 19-2346 (https://static.nhtsa.gov/odi/tsbs/2019/MC-10169807-0001.pdf) needs to include 2016 models of the Ford Fusion. My wife was starting our 2016 Ford Fusion 2.0l EcoBoost when it started shaking violently in idle. The check engine light began flashing. We had it towed into Ford where they are now quoting us a $10,000 full engine replacement for -??coolant in the cylinders.-?? This is the exact same problem the 2017-19 fusions are experiencing, so I am not sure why the 2016 isn-??t on this list.

- Renton, WA, USA

Coolant leaking into Engine

- Dallas, TX, USA

The car is missing on cylinder #1 and showing signs of a blown head gasket. Car will stall at random times as well. This is car has a the 1.5 ecoboost with a flway in the block design. Ford told me because of the flaw that I would have to purchase a new engine. There is currently a TSB out for this exact reason, yet ford wants me to pay for their mistake.

- Hemet, CA, USA

I have a 2016 Fusion with a 1.5 L EcoBoost, 54,000 miles on it. I am out of warranty by less than a year. My car told me that the engine was overheating while I was driving down the highway. I pulled off the road, and found there was no coolant in the reservoir. I filled the coolant up and kept an eye on it while scheduling a repair appointment. Every time I would drive the car, it would stutter when accelerating, only when it was cold. Once it warmed up it was not an issue. Every time I would also have to refill the coolant. I took the vehicle in, and found out it was misfiring on cylinder 4, and the coolant was leaking into the engine. Since it is out of warranty, it is $3,000 out of pocket. My car could have started on fire, or started smoking from the engine and caused a major accident had this gone on for too long. The misfire of the cylinder did not cause any warning lights to go on in my car. It would throw a code for a little bit, then disappear, it was a soft code not a hard code.

- Pewaukee, WI, USA

In September 2021 my 2016 Ford Fusion that has a 1.5L Eco boost engine had white smoke emitting from the exhaust. A check engine light came on and a test revealed that the #3 spark plug or ignition coil as bad. I had all spark plugs and ignition coils replaced. The light went off and three days later the check engine light came back on. We took it to Bob Tomes Ford 950 S Central Expy, McKinney, TX 75072. A Service inspection revealed that engine coolant was leaking into the cylinders and could potentially cause engine over heating and possibly a fire. This has been a known problem and numerous Service Bulletins (TECHNICAL SERVICE BULLETIN 1.5L EcoBoost - Low Coolant, White Exhaust Smoke And/Or Illuminated MIL - Built On Or Before 06-Apr-2019 19-2139) have been released on this issue, A compete engine replacement is the only repair option due to the original engine design since 2010 was a defective design which Ford actually recalled in the 1.6L engine but not the 1.5L. Ford Motor Company requires the consumer to bare the cost of repairs. My vehicle warranty was out by 2 months when this problem started at 82,000 miles. There is currently a law suit filed for this issue in U.S District Court for the Eastern District of California, Case # 2-2021cv00468. filed March 15, 2021.

- Wylie, TX, USA

Water seeping into cylinders causing engine warning light, missing, stalling and lost horsepower. Problem was found upon Dealership doing a pressure test and removing spark plugs to see the issue and confirmed. Water loss was being noticed during oil changes couple years before this incident. Last oil change 1200 miles ago noticed a big loss of water in the reservoir. First warning light appear 2 months ago but cleared a couple days later until this last warning light a week ago with noticeable performance issue.

- Shelby, AL, USA

Internal coolant leak inside cylinder causing misfire told engine could catch fire

- Cleveland , OH, USA

The engine block failed, cracking, causing coolant to leak into the number 3 cylinder. Causing a misfire code. I could hear what sounded like water flowing behind the dash for awhile. Eventually noticed I was a little low on coolant, then ended up using a whole gallon of coolant in about a week. The dipstick also had coolant on it when I checked the oil level. The car has been at the shop since January 23rd, 2021, they tested the head and it was fine. When I noticed it was a serious issue, coolant was blowing out the tail pipes in white clouds. I have a short video of this happening.

- Atkins, IA, USA

Vehicle is not cooling off

- Lebanon, KY, USA

Coolant leaked into engine causing cylinder 2 misfire and is now requiring an 8 thousand dollar repair for the whole engine.

- Burnsville, MN, USA

My fusion has had a rough idle when starting for the past year. I took it in to the mechanic and they said the problem was due to a backfire. They replaced the spark plugs and coils for around $500-$600. About 5 months later, I get e check engine light and a warning that the engine is overheating. Take it to the mechanic, where they figured out that this consistent issue is due to a head gasket leak, where coolant is going into the engine. From doing research, I have noticed that Ford Fusions with an eco boost engine have a poor engine manufacture and that this issue is prevalent in most eco boost engines. The new fix seems to be ranging from $1,200, and I have tried to diagnose this issue multiple times. This isn't easily distinguished by the engine warning, and can run the risk of drivers driving with lower amounts of engine coolant. If the engine overheats it can make the engine catch on fire. Although this did not happen to me yet, it has been months to diagnose this issue, only to find out that it is due to the engine model, and that leaving it untreated can cause serious damage to me and the engine.

- Tacoma, WA, USA

Vehicle overheats. Filled up coolant reservoir twice in one week. Checked coolant, coolant low, no leaks, no water going into the oil, coolant evaporates and causes car to overheat.

- Bakersfield, CA, USA

Coolant leaking into engine, 5 year old car with only 50K miles. Tons of information online about similar issues around the country but Ford has not acknowledged that it-??s a design flaw. Local dealer wants 10K dollars to replace engine.

- Bellevue, WA, USA

The contact owns a 2016 Ford Fusion. The contact stated while turning on the vehicle, the check engine warning light was illuminated. The vehicle was taken to an independent mechanic who diagnosed that there was a misfire detected in cylinder # 1. the check engine warning light was reset. The independent mechanic suggested that the vehicle be driven for a couple of miles to see if the check engine warning light would reappear. During the drive, the contact noticed that there was white smoke coming from the exhaust pipe and an overheat alert message appeared on the display. The contact researched online and saw that there was a technical service bulletin related to the failure and had the vehicle towed back to the same independent mechanic. The vehicle was diagnosed and the contact was informed that the long block was cracked and the engine needed to be replaced. The manufacturer was made aware of the failure. The failure mileage was 61,907.

- Niagara Falls, NY, USA

I bought my 2016 Fusion two years ago with 75,000 Miles on the odometer. The first day it went into fail safe mode while in the passing lane. I had no engine power and had to pull over in traffic. Code P2111 Throttle body stuck open. I cleaned the throttle body and maf sensor with a $10 two pack of spray cleaner. My car now with 110,000 miles just did the same thing yesterday 5/17/21 while in traffic code P2111. I cleaned the throttle body again even though it didn't look dirty compared to the first time. My car shut down three times today while in traffic. Each time I had to pull over with no power shut off the car and restart the engine. I will replace the throttle body but believe this is very serious defect and should have never happened at 75,000 miles or even at 110,000. Very dangerous and scary to drive far from home knowing how much it would cost to be towed and have to pay a shop to repair. Kind regards, [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

- Summerville, SC, USA