About this problem
Coolant intrusion means engine coolant is leaking inside the engine, usually into the cylinders, rather than dripping outside. On some engines the cylinder head and block design lets coolant seep past the head gasket area. The signs are a coolant level that keeps dropping with no visible leak, white exhaust smoke, misfires and overheating. Caught late, it can ruin the engine.
Across all owner complaints filed about the Ford Fusion since 2012, 1,364 (12.1%) describe coolant loss and engine overheating, the second most reported problem we track on the Fusion. The reports cluster on the 2016, 2017 and 2018 model years, and the 2016 drew the most, with 306. It tends to show up at higher mileage: half of the owners who gave a mileage were between 72,000 and 120,000 miles. 37 reports describe a crash or fire linked to it. 4 recalls are related to it, and recall repairs are free at any dealer.
What owners report
Owners of 2015 to 2019 Fusions with the 1.5- and 2.0-liter EcoBoost engines report coolant disappearing, overheating, misfires and white exhaust smoke. In many cases the coolant is leaking inside the engine into the cylinders, which ruins the engine. The 2016 to 2018 cars drew the most reports.
How it gets fixed
Most cases end with a replacement engine or short block with an updated design. Some cars got extended warranty coverage.
Typical cost: A replacement engine costs about $6,000 to $12,000 out of warranty.
Complaints by model year
In owners' words
"On february 11th 2020, I purchased a 2016 Ford Fusion with 73,000 miles from american car center in west columbia, s c. On february 23rd I was riding on i26 and my car started overheating. I pulled into a parking lot."
2016 Ford Fusion, 73,000 miles
"I / the owner of my 2017 Ford Fusion se 1.5l had a seized engine occur on my commute home from work. White smoke billowed and brewed out my exhaust as I was in the right lane."
2017 Ford Fusion, 76,000 miles
"Overheating message displaying. For safety the car has a low power mode and it activates. Letâs vehicle sit for 20 mins. Adding coolant lifted the hood container appeared to be empty. Purchasing the ORANGE! coolant auto zone suggested."
2018 Ford Fusion, 114,817 miles
Excerpts from public owner complaints filed with the National Highway Traffic Safety Administration, lightly trimmed.
Related recalls
Ford Motor Company (Ford) is recalling certain 2014 Escape, 2014-2015 Fiesta ST, 2013-2014 Fusion and 2013-2015 Transit Connect vehicles equipped with 1.6L GTDI engines.
This is an update to a recently announced recall.
Ford Motor Company (Ford) is recalling certain 120V Convenience charge cords that were supplied with and sold for use with 2013-2015 Ford C-Max Energi and Fusion Energi vehicles and 2012-2015 Ford Focus Electric vehicles.
Ford Motor Company (Ford) is recalling certain 2016-2019 Lincoln MKC, 2016-2023 Explorer, 2019-2020 Fusion, 2019-2024 Ranger, 2020-2022 Lincoln Corsair, Escape, 2021-2024 Bronco, Bronco Sport, and 2022-2024 Maverick vehicles.
Recall repairs are free at any dealer. Check a specific car by VIN at nhtsa.gov/recalls.
Service bulletins
Ford has sent dealers 25 bulletins that mention this problem on the Fusion. A bulletin tells technicians how to fix a known fault. It is not a recall, so the repair is usually free only while the car is under warranty or covered by an extension.
SSM 48659 - 2019-2020 Fusion/MKZ - Cooling Fans Inoperative Due To Open Fuses F59, F60 And F63 Some 2019-2020 Fusion/MKZ non-hybrid vehicles may exhibit an engine overheat condition or a lack of air conditioning (A/C) cooling d...
Some 2014-2019 Fusion and 2017-2019 Escape vehicles equipped with a 1.5L EcoBoost engine may exhibit coolant consumption and white smoke concern.
Some 2014-2019 Fusion and 2017-2019 Escape equipped with 1.5L EcoBoost engine may exhibit coolant consumption and white smoke concern.
Some 2015-2018 Edge and 2015-2019 Fusion/MKZ/Escape/MKC vehicles equipped with a 2.0L EcoBoost engine may exhibit a low coolant level, white exhaust smoke and/or a runs rough condition with or without an illuminated malfunction...
Some 2015-2018 Edge and 2017-2019 Fusion/MKZ/Escape/MKC vehicles equipped with a 2.0L EcoBoost engine may exhibit a low coolant level, white exhaust smoke and/or a runs rough condition with or without an illuminated malfunction...
Some 2014-2019 Fusion and 2017-2019 Escape vehicles with 1.5L EcoBoost engine exhibiting coolant consumption and white smoke from the exhaust.
Before you buy a Fusion
- Check the coolant level when the engine is cold, and look for a low or empty reservoir.
- Watch for white smoke at start-up and ask about misfires.
- Ask whether the engine has been replaced and with which part.
Questions
Which Ford Fusion years have coolant loss and engine overheating?
Complaints are highest for the 2016, 2017, 2018 model years. The 2016 drew the most, with 306 reports.
At what mileage does it usually start?
Among owners who gave a mileage, the middle figure was about 92,000 miles, and half reported it between 72,000 and 120,000 miles.
How much does it cost to fix?
A replacement engine costs about $6,000 to $12,000 out of warranty.