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full bulletin at NHTSA ↗2009 Ford Fusion engine problems
severe Owners of the 2009 Ford Fusion have filed 17 NHTSA complaints about the engine, typically surfacing around 108,252 miles at roughly $3,100 to repair (U.S. federal records, as of August 2026). Source: NHTSA Office of Defects Investigation. See engine across all vehicles →
Failure mileage
Complaints
17
Recalls
0
Avg fix
$3,100
| Model year | engine complaints |
|---|---|
| 2006 Fusion | 25 |
| 2007 Fusion | 35 |
| 2008 Fusion | 17 |
| 2009 Fusion (this page) | 17 |
| 2010 Fusion | 282 |
| 2011 Fusion | 90 |
| 2012 Fusion | 49 |
| 2013 Fusion | 314 |
2fires
1injury
Is there a fix? Manufacturer service bulletins
The manufacturer has issued service bulletins covering engine on this vehicle — documented repair instructions, service campaigns, or warranty extensions sent to dealers. A TSB isn't a recall (it's not a free safety remedy), but it's the manufacturer acknowledging the issue and how to fix it.
The Powertrain Control/Emissions Diagnosis (PC/ED) manual has been revised for diagnosing electronic throttle bodies (ETBs). The ETC_ACT and ETC_DSD PIDs should not used to diagnose possible ETB concerns. The IDS has a limited refresh rate when reading these PIDs and cannot display quickly enough to validate a concern. The PCM automatically monitors these inputs more accurately and will set diagnostic trouble codes (DTCs) when appropriate. Using these PIDs for diagnostics will lead to inaccurate results and improper ETB replacements. If a concern is intermittent and no DTCs are present, refer to historical DTCs and the PC/ED, Section 3 No DTCs Present Index chart for further information.
full bulletin at NHTSA ↗FORD: IF THERE IS AN INTERMITTENT LACK OF POWER, SURGE, OR HESITATION WHILE DRIVING THE BRAKES WILL OVERRIDE ACCELERATION.
full bulletin at NHTSA ↗FORD/MERCURY: SOME VEHICLES MAY EXHIBIT A MALFUNCTION INDICATOR LIGHT (MIL) ON WITH DIAGNOSTIC TROUBLE CODES (DTCS) P0340 AND/OR P0344 (CAMSHAFT POSITION SENSOR CIRCUIT). MAY BE DUE TO INCORRECT READING FROM THE CAMSHAFT SENSOR.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners report two major engine problems in the 2009 Fusion. First, catastrophic engine failure from rod knock: sudden loud explosion under acceleration with complete loss of power steering and braking, heavy smoke from the engine bay and into the cabin, and in one case a piece of the engine block fell out. One owner faced this twice—the dealer replaced the engine after the first failure, but it blew again 90,000 miles later with identical symptoms.
Second, electronic throttle body defects cause the engine to stall without warning during normal driving or at intersections. Owners report the vehicle enters "limp mode," loses acceleration ability, and cannot be trusted to merge or clear intersections safely. Ford had a consumer satisfaction program (13N03) for this defect, but some owners were denied coverage despite having the identical failure. Even after throttle body and EGR valve replacement, stalling persisted in at least one vehicle.
Additional failures reported: stuck exhaust manifold valve (check engine light, recurred immediately after repair), oil dip stick assembly screws loosened causing complete oil loss (dealer was aware of the defect), engine fire at highway speed with smoke inhalation injury, and one complete engine stall on highway with wrench light and no restart capability at roadside (started right up at the shop with no diagnostic codes found). No owner reported adequate warning before these failures occurred.
Same Ford Fusion engine reports on nearby years: 2007 · 2008 · 2010 · 2011 · 2012
Failure modes owners describe
Rod knock / catastrophic engine failure
Engine threw a rod with sudden loud explosion, loss of power steering and braking, heavy smoke from engine bay. Happened during acceleration after highway merge; no warning lights or prior noise. One complaint repeated failure: original engine blown, replaced by dealer, new engine then failed again at 90k miles with sudden power surge, loud bang, white smoke, oil loss, and piece of engine fell out.
When: First failure July 10, 2009 at approximately 68k-70k miles; second failure at 139,000 miles (90k after first replacement)
Symptoms owners cite: Loud explosion or bang from engine; Sudden loss of power; Violent vehicle jolting or bucking; Heavy smoke from engine compartment and undercarriage; Smoke pulled into cabin via HVAC; Loss of power steering and braking (power cut off); Engine oil and internal parts visible on ground
Repairs/costs cited: Ford replaced entire engine assembly and miscellaneous damaged components. Second failure also required engine replacement.
Electronic throttle body malfunction
Electronic throttle body defect causing vehicle to enter limp mode, stall without warning, lose power, and run at reduced speeds. Owners report inability to accelerate safely, especially at intersections. One complaint mentions defect addressed by Ford Consumer Satisfaction Program 13N03 but owner's vehicle denied coverage. Another complaint references NHTSA action PE13003 (ENGINE) related to electronic throttle body replacement.
When: Various mileages: 35 mph stall at 215,000 miles; limp mode on highway; stalling during normal driving
Symptoms owners cite: Vehicle enters limp mode; Stalling without warning; Loss of power during acceleration; Reduced engine speed; Inability to accelerate safely from stops or intersections; Inconsistent starting behavior
Codes mentioned: P2112, P0721, P2104
Repairs/costs cited: Electric throttle body replaced by dealer. Throttle body replacement mentioned in another complaint, but stalling persisted after replacement of both throttle body and EGR valve.
Recalls/TSBs owners mention: Ford Consumer Satisfaction Program 13N03 addresses throttle body defect; NHTSA action PE13003 referenced; owner denied coverage by Ford despite identical defect to program
Engine stalling / loss of power / limp mode
Multiple complaints of engine stalling during normal driving or at stops with no warning lights in some cases. Vehicle loses all power (steering and braking). In one case, loud clanking noise preceded stall; diagnosis was complete engine failure. Stalling persists even after throttle body and EGR valve replacement in one complaint.
When: Various conditions: pulling away from stop signs, normal highway speeds (70 mph), 35 mph, after complete stops, mileage range 50-215k miles
Symptoms owners cite: Engine stalls without warning; No power steering or braking during stall; Loud clanking noise before failure (in one case); Wrench light illuminated; Check engine light; Inconsistent stalling pattern (approximately weekly in one case)
Codes mentioned: POD DATA ERROR
Repairs/costs cited: Throttle body replaced; EGR valve replaced; one stall at 50 mph with clanking sound required new motor; stalling persisted after multiple repairs in one complaint
Recalls/TSBs owners mention: Manufacturer referred complainants to NHTSA Hotline
Stuck exhaust manifold valve
Exhaust manifold valve stuck in open position, causing check engine light. Failed twice at independent mechanic; second failure not repaired. Manufacturer referred owner to NHTSA.
When: Unknown mileage
Symptoms owners cite: Check engine light illuminated; Exhaust manifold valve stuck in open position
Repairs/costs cited: Repaired once; reoccurred immediately; not repaired second time
Recalls/TSBs owners mention: Manufacturer referred contact to NHTSA Hotline
Engine fire / smoke and overheating
Smoke visible from engine compartment at low speed (15 mph), then popping noise from engine, fire started. Check engine light illuminated. Fire department extinguished fire. Owner sustained smoke inhalation.
When: 200,000 miles
Symptoms owners cite: Smoke from engine compartment; Popping noise from engine; Fire in engine compartment; Check engine light; Smoke inhalation injury to occupant
Repairs/costs cited: Vehicle towed to residence, not repaired
Oil dip stick assembly failure / oil loss
Oil dip stick assembly screws loosened, resulting in no engine oil in vehicle. Dealer was aware of this failure. Owner not informed until discovered during routine check.
When: 114,000 miles
Symptoms owners cite: No engine oil visible on dip stick; Oil dip stick assembly screws loosened
Repairs/costs cited: Vehicle not repaired; dealer and manufacturer contacted
Recalls/TSBs owners mention: Manufacturer referred contact to NHTSA Hotline
Throttle response / acceleration issues
Floor mats getting stuck on gas pedal causing engine to race and making it difficult to stop vehicle. Not technically an engine defect but creates engine racing condition.
When: First month of ownership at 68k miles
Symptoms owners cite: Floor mats stuck on accelerator pedal; Engine racing; Difficulty stopping vehicle
Repairs/costs cited: Fusion floor mats discarded by owner; no repair attempted
Synthesized from 17 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 0 most recent
Had engine trouble with your 2009 Ford Fusion?
File a complaint with NHTSA → It's free, official, and how every report above got here — owner filings are the federal safety record this page is built on.
Common questions
How serious is the engine problem on the 2009 Ford Fusion?
It's a meaningful issue. 17 complaints have been filed and the failure mode causes operational problems for owners. Repairs average $3,100.
At what mileage does the engine typically fail?
Across the 15 complaints that reported odometer mileage, most engine failures cluster between 81,000 and 132,000 miles, with the median around 108,252. A quarter of owners report trouble before 81,000; a quarter make it past 132,000. Maintenance history matters more than the odometer alone — this is the reported failure window, not a guarantee.
What does it cost to fix?
Independent shops typically charge around $3,100 for engine repairs on this vehicle. Dealer pricing tends to run 20-40% higher. The exact figure depends on the specific failure mode, parts availability, and your local labor rates. If you're outside factory warranty, an extended service contract often covers this category.
Are there any recalls related to engine?
No active recalls currently cover engine issues on this vehicle. The complaints filed represent owner-reported failures that haven't risen to the level of a manufacturer-issued recall — but they're still worth knowing about before you buy or budget for repairs.
Related
Complaint and recall data sourced from the National Highway Traffic Safety Administration (NHTSA)
public records database. Verify the raw federal record at
nhtsa.gov/vehicle/2009/Ford/Fusion.
Severity ratings are derived from reported crashes, fires, injuries, and fatalities. Repair cost estimates are
independent-shop national averages and may differ in your area. Some links on this page are affiliate links.