The 2013 Fusion fuel system shows a cluster of distinct problems across these 22 complaints. The most dangerous is sudden loss of engine power while driving—throttle becomes unresponsive at highway speeds or in traffic, vehicle limps along at 5–25 MPH, engine revs without providing acceleration, and only a complete shutdown restores responsiveness. One owner experienced this twice despite a recalled fuel pump replacement.
Fuel leaks and tank cracking are widespread. Owners report strong gasoline odor inside and outside the vehicle, fuel pooling under the engine compartment, and cracked fuel delivery modules or canisters requiring replacement. Many owners say their VINs were excluded from recall campaign 13V227000 despite matching the failure description exactly.
Tank filling is broken on many units. A 16.5-gallon tank accepts only 12–13 gallons even after multiple pump top-offs. Ford engineering acknowledged the issue internally but offered no timeline for a fix. Forums cite TSB 13-6-3 and report fuel tank replacement solves it.
Other reported failures include rough idle and delayed throttle response at low speeds, EVAP purge valve cracking, loose fuel filler caps letting air into fuel lines, and one vehicle fire of unknown origin. One owner's vehicle stalled repeatedly and required towing; another had poor fuel economy well below EPA figures. Dealers often demand $180+ just to scan the computer, and many owners report manufacturer or dealer refusal to help because their VINs aren't included in recall campaigns.
Failure modes owners describe
Sudden loss of engine power / limp-mode derating
Engine continues running but throttle becomes unresponsive, vehicle loses acceleration and drops into limp-home mode limiting speed to 5-25 MPH. Occurs while driving at highway speeds or in intersection. Engine revs without providing propulsion. Requires full shutdown to restore responsiveness.
When: While driving at various speeds (25 MPH, 75 MPH); second occurrence reported by one owner
Symptoms owners cite: No response to accelerator pedal despite engine running; Engine RPMs increase without vehicle acceleration; Sudden drop in speed from 75 MPH or 25 MPH; Limp-mode operation with max speed 5-25 MPH; Vehicle requires complete shutdown and restart to restore power
Codes mentioned: Multiple error codes reported (one complaint mentions 50 codes); throttle body issue suspected by owners
Repairs/costs cited: One owner had fuel pump replaced under recall but issue persisted; exact root cause unclear from narratives
Recalls/TSBs owners mention: Recalled fuel pump replacement did not resolve issue; no TSB or additional remedy mentioned
Fuel delivery module / tank cracking and fuel leaks
Fuel leaking from fuel tank or fuel delivery module cracks, allowing gasoline to pool underneath engine compartment. Strong fuel odor inside and outside vehicle. Multiple owners report VINs not included in recall campaign 13V227000 despite experiencing identical failure.
When: 85,000 miles to 160,000 miles; one occurrence at 36,816 miles for A/C issue possibly related
Symptoms owners cite: Strong gasoline odor inside and outside vehicle; Visible fuel leaking underneath engine compartment or from fuel tank area; Fuel puddle visible when parked or driven home; Check engine light illuminated in some cases
Codes mentioned: Check engine light, Service engine indicator
Repairs/costs cited: Fuel delivery module replacement needed; fuel tank replacement reported on forums as fixing the fill issue (TSB 13-6-3); not yet completed on several vehicles
Recalls/TSBs owners mention: NHTSA Campaign 13V227000 (Fuel System, Gasoline); many owners informed their VINs excluded; manufacturers advised contact NHTSA Hotline or refused assistance
Fuel tank fill-level inaccuracy and reduced tank capacity
Fuel gauge reading inaccurate; tank will not fill to full capacity. Vehicle with 16.5-gallon tank will only accept 12.86-13 gallons even after multiple pump top-offs. Ford engineering acknowledged internal knowledge of issue but offered no solution timeline. Some dealers attribute problem to intentional fuel gauge reserve design allowing 20+ percent reserve after zero-miles reading.
When: 35,000+ miles; issues reported across mileage range
Symptoms owners cite: Tank will not fill beyond 12-13 gallons despite 16.5-gallon capacity; Multiple pump click-offs needed; Fuel gauge reading discrepancies; Unable to accurately assess fuel level
Repairs/costs cited: TSB 13-6-3 exists; forum reports indicate fuel tank replacement resolves problem; repair not yet completed on complaint vehicles
Recalls/TSBs owners mention: Ford engineering acknowledged awareness of issue and stated they were working on solution (per dealership service adviser); TSB 13-6-3 referenced but some owners report Ford refuses to address
Hard idle and rough running at low speeds / throttle response lag
Vehicle idles harshly with RPM fluctuation and nearly stalls when coming to stop. Delayed or no response when pressing accelerator at low speeds (0-10 MPH), then sudden aggressive acceleration when vehicle finally responds. No warning lights displayed despite driveability problems.
When: Approximately 33,000 miles; across various mileage points
Symptoms owners cite: Hard, rough idle with RPM drop at stops; Vehicle acts like it will stall; No throttle response or delayed response at low speeds; Sudden rapid acceleration when vehicle responds; Unpredictable throttle behavior
Repairs/costs cited: One owner mentions dealership wanted $180 diagnostic fee; no repairs documented in narratives
Recalls/TSBs owners mention: No recalls on specific vehicle VINs; dealership refused to diagnose under warranty
EVAP system failure / purge valve and fuel canister issues
EVAP purge valve cracks or fails; fuel tank canister requires replacement. Abnormal sounds from fuel tank; fuel odor detected inside vehicle. Check engine light illuminates. Vehicle at 72 MPH began shaking and stalled with difficulty restarting.
When: 99,000 to 197,000 miles
Symptoms owners cite: Abnormal sound from fuel tank; Fuel odor entering vehicle cabin; Vehicle shaking and stalling while driving; Multiple restart attempts needed; Check engine light illumination
Codes mentioned: Check engine light illuminated
Repairs/costs cited: EVAP system or purge valve replacement needed; parts not available at time of complaint on at least one vehicle
Recalls/TSBs owners mention: NHTSA campaign 15V793000 (Fuel System, Gasoline) referenced but vehicle not included; no manufacturer assistance offered
Fuel filler flap not sealing / air entering fuel lines
Fuel filler flap does not seal tightly, allowing air to enter fuel lines and tank. Service engine indicator illuminates randomly.
When: 70,000 miles
Symptoms owners cite: Fuel flap loose or not sealing properly; Service engine indicator illuminating randomly; Air entering fuel system
Codes mentioned: Service engine indicator
Repairs/costs cited: Fuel flap replacement needed
Recalls/TSBs owners mention: Vehicle not included in any recalls per manufacturer notification
Vehicle fire with unknown origin in fuel system area
2013 Fusion Hybrid developed black smoke from rear seats area while being driven. Driver pulled over, evacuated vehicle, and entire vehicle caught fire. Fire Department indicated fire may have originated from trunk area. Driver's side burned more severely than rest of vehicle. Vehicle towed and potentially totaled. Occupants treated for smoke inhalation.
When: Unknown mileage; unknown speed
Symptoms owners cite: Black smoke observed from rear seats area; Vehicle engulfed in flames; Fire concentrated on driver's side; Smoke inhalation to occupants
Repairs/costs cited: Vehicle totaled by fire
Recalls/TSBs owners mention: Manufacturer and dealer not notified; Fire Department responded
Engine stalling and shutdown during driving or shifting
Vehicle stalls suddenly without warning while driving or when shifting into Drive from Park. Engine shuts off requiring multiple restart attempts. Check engine light or mechanical symbol illuminates on instrument cluster.
When: 35,000 miles; while backing out of driveway at low speed
Symptoms owners cite: Sudden stalling without warning; Vehicle shuts off when shifting from Park to Drive; Difficulty restarting (multiple attempts required); Check engine or mechanical symbol on dashboard
Codes mentioned: Check engine light, Mechanical symbol on instrument cluster
Repairs/costs cited: One owner had fuel pump replaced; another vehicle at dealership with unresolved issue
Recalls/TSBs owners mention: No repairs completed or solutions offered in narratives
Poor fuel economy below manufacturer estimates
Vehicle fuel economy significantly below EPA estimates and below comparable earlier model year. 2013 EcoBoost 4-cylinder achieving only 19 MPH city / 31 MPH highway maximum, compared to better performance on owner's 2012 V6 model. Manufacturer and dealer claim vehicle operating as designed and MPG figures are estimates only.
When: 33,000 miles to throughout ownership
Symptoms owners cite: Fuel economy 19 MPG city or less; Highway fuel economy not exceeding 31 MPG; Poor performance relative to V6 predecessor and EcoBoost marketing; No warning lights or diagnostic codes
Repairs/costs cited: No repairs documented
Recalls/TSBs owners mention: Dealer and manufacturer advised vehicle operating as designed; MPG advertised as estimate only
Synthesized from 22 NHTSA owner complaints — unverified consumer
allegations, summarized for patterns. The verbatim filings appear below.