The contact owns a 2016 Ford Fusion. The contact stated that while driving at an undisclosed speed, he observed smoke emanating from the engine compartment, after which a message displayed reading "High Engine Temperature". The check engine and temperature warning lights were illuminated. The vehicle was taken to the dealer, who determined that coolant intrusion had damaged the engine and the engine needed to be replaced. The vehicle was not repaired. 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 96,000.

- Hartford, CT, USA

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 would not feel comfortable having that done and would want a crate engine as the other components would now be compromised. I have spent $1200 on replacement coil packs and spark plugs, coolant and oil, all to treat the symptoms. In addition to Fords $260 diagnostic fee at the dealer for a known defect. Ford should not get away with bilking customers for $10,000 plus engine rebuilds - this would likely not last the same miles it has gone currently in my case.

- Richland , WA, USA

The contact owns a 2016 Ford Fusion. The contact stated that when he started the vehicle in the mornings he noticed that it would idle roughly and large amounts of white exhaust was issued from the exhaust pipe. The contact stated that the check engine light was illuminated. Additionally, the contact noted that the vehicle was consuming unusual amounts of coolant that required him to fill the coolant reservoir every week with approximately one quart of coolant. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that coolant had intruded into the engine cylinders. The contact was advised that the engine block needed to be replaced. The vehicle was not repaired. The manufacturer was informed of the failure. The contact had researched online and related the failure to manufacturer Technical Service Bulletin Number: 19-2139 Coolant Intrusion into the Cylinder (Engine and Engine Cooling). The failure mileage was approximately 96,000.

- Clifton, NJ, USA

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.

- Cochran, GA, USA

The contact owns a 2016 Ford Fusion. The contact stated that while her husband was driving at 70 MPH, the temperature started indicating that the engine was overheating, with a message -??Engine temperature high-?? displayed. The check engine warning light was illuminated. The vehicle was taken to the dealer, who determined that the engine was low on oil, resulting in damage to the engine. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure but referred the contact to the NHTSA Hotline for assistance. The failure mileage was 102,000.

- Owensboro, KY, USA

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.

- Crossett, AR, USA

The contact owns a 2016 Ford Fusion. The contact stated that the check engine warning light was illuminated. The contact stated that the battery had failed several times and was replaced approximately 5 times. The contact also stated there was exhaust coming out of the tailpipe during the initial start-up. The vehicle was taken to the dealer and was repaired under NHTSA Campaign Number: 23V162000 (Service Brakes, Hydraulic). The dealer diagnosed the vehicle and determined that the alternator was producing 20 volts while accelerating, causing the battery to overheat and burn out. Additionally, cylinder #3 was misfiring due to anti-freeze leaking into the engine. The contact was informed that the engine needed to be replaced. The vehicle had not been repaired. The manufacturer was made aware of the failure and it was confirmed that there were no recalls related to the failure. The contact was referred to the NHTSA Hotline to file a complaint. The failure mileage was 142,728.

- Yarmouth, ME, USA

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 the contact that the VIN was not included in an unknown recall due to the plant where the vehicle was manufactured. The manufacturer referred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 130,000.

- Raleigh, NC, USA

The contact owns a 2016 Ford Fusion. The contact stated while driving approximately 60 MPH, the vehicle was driving rough. The contact stated that the vehicle was overheating. The contact noticed white smoke coming from the vehicle. There were no warning lights illuminated. The vehicle was taken to the local dealer, where it was diagnosed that there was coolant intrusion into the short block. The vehicle was not repaired. The manufacturer was contacted and referred the contact to the NHTSA Hotline. The failure mileage was approximately 52,500.

- Brunswick, OH, USA

The contact owns a 2016 Ford Fusion. The contact stated that while her daughter was driving at an undisclosed speed, the vehicle began to overheat, and the vehicle lost motive power. The contact's daughter was able to pull over to the shoulder of the roadway, where the vehicle was able to be restarted. The overheating warning light was illuminated. The vehicle was taken to the dealer, who diagnosed a general engine failure. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, and a case was filed. The failure mileage was 150,000.

- Homestead, FL, USA

The contact owns a 2016 Ford Fusion. The contact stated while driving 35 MPH, the vehicle started to vibrate and would also vibrate at various speeds. The contact stated that the vehicle was idling rough at start-up. The contact stated that the check engine warning light was illuminated. The contact had taken the vehicle to an independent mechanic who diagnosed and determined that the spark plugs needed to be replaced and the fuel injectors needed to be cleaned. The vehicle had been repaired; however, the failure reoccurred. The contact took the vehicle to another independent mechanic and was advised that coolant had leaked into the engine block and the engine needed to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The contact researched online and related the failure to TSB: 19-2139 - Coolant Intrusion into the Engine Block (Engine and Engine Cooling). The failure mileage was approximately 130,000.

- Arcata, CA, USA

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed and depressing the accelerator pedal, the vehicle shuddered significantly. There was no warning light illuminated. The contact stated that the failure had been recurring while driving. Additionally, the contact stated that the failure recurred while driving from a complete stop while the engine revved to 1500-2000 RPMs. The vehicle was taken to the dealer, where it was diagnosed that there was coolant intrusion into engine cylinder #3. The vehicle was not repaired. The manufacturer was notified of the failure and transferred the contact to the NHTSA Hotline for assistance. The failure mileage was approximately 87,000.

- Nicholasville, KY, USA

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.

- Greensburg, PA, USA

The contact owns a 2016 Ford Fusion. The contact stated while the vehicle was idling, there was white smoke coming out of the exhaust pipe. Upon inspecting the vehicle, the contact noticed that the coolant level was significantly low. The vehicle was taken to an independent mechanic, where it was diagnosed with combustion gases in the cooling system. The mechanic determined that the failure was related to TSB Number: 20-2100. The dealer was notified of the failure and informed the contact that he would be charged a fee for the repair because the vehicle was out of warranty. 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 approximately 163,185.

- Camden, ME, USA

The contact owns a 2016 Ford Fusion. The contact stated that on several occasions after refilling the coolant, while driving at an undisclosed speed, the vehicle inadvertently decelerated and failed to accelerate over 20 MPH. The check engine warning light illuminated. The contact then stated that the vehicle started to overheat. The vehicle was taken to an independent mechanic where it was diagnosed that the spark plugs, ignition coil, and undisclosed multiple sensors needed to be replaced. The vehicle was repaired; however, the failure recurred. The vehicle was taken to an independent mechanic to be diagnosed. The mechanic retrieved DTC Code: P0303: (Cylinder #3 Misfire). The contact also stated that he was informed that coolant had leaked into the cylinder and the engine needed to be replaced. The vehicle was not repaired. An undisclosed dealer was notified of the failure. The manufacturer was notified of the failure and the contact was advised to contact the NHTSA Hotline for assistance. The failure mileage was approximately 120,000.

- Houston, TX, USA

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.

- Lakeville, MN, USA

The contact owns a 2016 Ford Fusion. The contact stated while his son was driving 50 MPH, the vehicle started overheating, and there was white smoke coming out of the exhaust pipe. The check engine warning light was illuminated. The contact's son veered to the side of the road. The vehicle was towed to the residence. The contact stated that he was a certified independent mechanic, and he had diagnosed that there was a coolant intrusion in the exhaust system. The contact determined that the engine needed to be replaced. The dealer was not notified of the failure. 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 approximately 159,000.

- Inverness, FL, USA

The contact owns a 2016 Ford Fusion. The contact stated that while his wife was driving at an undisclosed speed, the coolant temperature warning light illuminated. The contact's wife pulled to the side of the roadway, turned off and restarted the vehicle; however, the failure persisted. The vehicle was taken to an independent mechanic, who diagnosed that coolant was leaking into the pistons, which caused the engine to overheat. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. There was no further information provided. 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 133,000.

- Harrodsburg, KY, USA

The contact owns a 2016 Ford Fusion. The contact stated while driving at 55-60 MPH, the vehicle was sluggish and hesitated to respond when depressing the accelerator pedal. There was no warning light illuminated. The contact stated that the failure recurred several times while driving. The contact stated that while driving at an undisclosed speed and making a turn, the accelerator pedal was depressed but the vehicle hesitated to respond, causing another vehicle to crash into the rear passenger's side of the vehicle. The contact was able to drive to the hospital, where he received medical assistance. The contact stated that he sustained whiplash and lower back pain, and he had received physical therapy. The contact was unsure whether the other driver had sustained injuries. A police report was filed. The contact stated that the failure later recurred and the check engine warning light was illuminated. The vehicle was taken to AutoZone, where it was diagnosed that the spark plugs and ignition coils of cylinder number 3 had failed. The contact stated that all the spark plugs and ignition coils were replaced; however, the failure persisted. Additionally, the temperature gauge indicated that the vehicle was overheating. Upon inspecting the coolant level several times, the contact noticed that there was abnormal coolant drainage. The contact stated that the vehicle failed to start. The vehicle was towed to the dealer, where it was diagnosed that there was coolant intrusion in the engine, and that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure, and a case was opened. The failure mileage was unknown.

- Eagle Mountain, UT, USA

The contact owns a 2016 Ford Fusion. The contact stated while driving 55 MPH, the check engine warning light illuminated. The vehicle was taken to the dealer the following day and was diagnosed that there was coolant intrusion in the engine piston rings. The contact was informed that the engine needed to be replaced. The vehicle was repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 60,990.

- Tipton, IA, USA