For 2015-2024 Ford and Lincoln vehicles equipped with turbocharged engines and customer concern of an engine oil leak, refer to Workshop Manual (WSM), Section 303-00 for oil leak inspection and testing methods. Ford has evaluated turbochargers replaced for oil leak symptoms and although oil may collect on the external surface of a turbocharger, it is extremely rare for a turbocharger assembly to be the root cause of the oil leak. Careful inspection of the turbocharger oil feed and drain tubes should be performed along with the recommended WSM procedures as needed. Warranty claims for turbocharger replacement going forward will be assessed.
full bulletin at NHTSA ↗2016 Ford Fusion engine problems
moderate Owners of the 2016 Ford Fusion have filed 446 NHTSA complaints about the engine, typically surfacing around 96,000 miles at roughly $3,100 to repair (U.S. federal records, as of July 2026). Source: NHTSA Office of Defects Investigation. See engine across all vehicles →
Failure mileage
Complaints
446
Recalls
0
Avg fix
$3,100
| Model year | engine complaints |
|---|---|
| 2012 Fusion | 49 |
| 2013 Fusion | 314 |
| 2014 Fusion | 157 |
| 2015 Fusion | 243 |
| 2016 Fusion (this page) | 446 |
| 2017 Fusion | 419 |
| 2018 Fusion | 212 |
| 2019 Fusion | 160 |
| 2020 Fusion | 26 |
2crashes
1fire
1injury
When does it fail?
Of the 446 engine complaints filed for the 2016 Ford Fusion, here's the actual mileage breakdown — failures cluster heaviest at 75,000-100,000 mi.
0-25k
25-50k
50-75k
75-100k
100-125k
125-150k
150k+
Each bar shows the share of total complaints filed at that mileage range. Peak failure window highlighted. Some owners report problems earlier; some make it well past 150,000 miles symptom-free. Maintenance habits and driving conditions shift the curve as much as mileage alone.
What stands out
Of the 15 model years of Ford Fusion we track for engine problems, this one carries the most owner complaints on file — 446.
Owners have filed 446 engine complaints with NHTSA against this vehicle, but no formal recall covers the issue — the federal record reflects what manufacturers have admitted, not everything owners are reporting.
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.
Some 2014-2020 Fusion and 2017-2019 Escape vehicles may be equipped with a 1.5L Ecoboost engine that uses a 50-tooth variable camshaft timing (VCT) intake and exhaust unit from the assembly plant or if a service long block was installed. VCT locking tool 303-1097 is not compatible with this system. If VCT system service is required, replace both the intake VCT (service part DS7Z-6256-F) and exhaust VCT (service part DS7Z-6256-G) as a pair. An interim loaner tool program has been established to enable these repairs. Contact 1-800-403-4844 (Monday-Friday 8:00am to 8:00pm EST; Saturday 8:00am to 3:00pm EST) to obtain this tool. A VCT locking tool compatible with the 50-tooth system is under dev
full bulletin at NHTSA ↗Some 2014-2019 Fusion vehicles built on or before 10-Jun-2019 and 2017-2019 Escape vehicles built on or before 08-Apr-2019 equipped with a 1.5L EcoBoost engine may exhibit low coolant level, white exhaust smoke and/or runs rough condition with or without an illuminated malfunction indicator light (MIL) with only diagnostic trouble codes (DTCs) P0300, P0301-P0304, P0316, P0217, P1285 and/or P1299 stored in powertrain control module (PCM). This may be due to coolant intrusion into the cylinder. To resolve the condition, follow the Service Procedure to replace the short block and head gasket.
full bulletin at NHTSA ↗Some 2014-2017 C-MAX Energi, 2014-2020 Fusion plug-in hybrid electric vehicle (PHEV), 2015-2017 MKZ/MKZ Hybrid/MKC, 2016-2017 MKX, 2016-2018 Focus battery electric vehicle (BEV) and 2017 Continental vehicles equipped with SYNC screens 8 inch or larger may be unable to complete modem authorization after 3G to 4G modem upgrade was performed. No Authorization Popup displayed on SYNC infotainment screen during the Authorization process. This may be due to the Sync Software. To correct the condition, follow the Service Procedure to toggle Valet Mode.
full bulletin at NHTSA ↗Some 2014-2019 Fusion vehicles built on or before 10-Jun-2019 and 2017-2019 Escape vehicles built on or before 08-Apr-2019 equipped with a 1.5L EcoBoost engine may exhibit low coolant level, white exhaust smoke and/or runs rough condition with or without an illuminated malfunction indicator light (MIL) with only diagnostic trouble codes (DTCs) P0300, P0301-P0304, P0316, P0217, P1285 and/or P1299 stored in powertrain control module (PCM). This may be due to coolant intrusion into the cylinder. To resolve the condition, follow the Service Procedure to replace the short block and head gasket.
full bulletin at NHTSA ↗Source: NHTSA manufacturer communications. Bring the bulletin number to your dealer or shop.
The failure pattern owners describe
Owners of 2016 Ford Fusions consistently report a coolant intrusion defect that Ford's own technical service bulletins (TSB 19-2139, 19-2346, 20-2100, 22-2134) acknowledge. Coolant leaks into one or more cylinders, starting a cascade of problems: misfire codes (P0301, P0302, P0304) trigger check engine lights; white smoke erupts from the exhaust; rough idle and hesitation become chronic; coolant disappears from the reservoir despite no visible external leaks; engines overheat without warning.
Owners spend hundreds replacing spark plugs and ignition coils multiple times—$500–$700 per visit—only to watch the check engine light return within days. Independent mechanics and some dealerships eventually uncover the true culprit: the engine block itself is flawed, with poor head gasket seals and compromised cylinder walls. Complete engine replacement (long-block) is the only lasting fix, costing $5,000–$14,000 or more, plus weeks or months of lead time due to parts shortages.
The danger is real. Owners report engine stalling at 55–70 mph on highways with no warning, sudden loss of all power mid-acceleration, and inability to restart until the engine cools. One owner lost braking response coinciding with engine failure. Ford has extended recalls for some 1.5L EcoBoost models through 2019, but many 2016 units—especially 2.0L models—are excluded by VIN or build plant despite identical symptoms. Owners outside warranty periods face refusals from Ford, even those with documented proof of defect. Some dealerships knew about the issue before owners brought their cars in and have observed multiple affected vehicles in their shops per month.
Same Ford Fusion engine reports on nearby years: 2014 · 2015 · 2017 · 2018 · 2019
Failure modes owners describe
Coolant intrusion into cylinders
Engine design flaw allows coolant to leak into one or more cylinders, causing misfires, rough idling, white exhaust smoke, and eventual engine failure. Ford acknowledges this as a known defect in EcoBoost engines, particularly 1.5L and 2.0L models, caused by compromised cylinder wall seals and head gasket design. Some 2017+ models received design corrections that were not applied to 2016 units.
When: Typically between 40,000–175,000 miles; often emerges around 55,000–130,000 miles
Symptoms owners cite: Check engine light (misfire codes P0301, P0302, P0304); Rough idle or hesitation on acceleration; White smoke from exhaust; Low coolant level with no visible external leak; Engine overheating warnings; Loss of power while driving; Vehicle stalling on highway or city streets; Abnormal knocking/vibration; Accelerator lag or sluggish response
Codes mentioned: P0301, P0302, P0304, P0299
Repairs/costs cited: Owners cite engine replacement costs ranging $5,000–$14,000+. Some report mechanics charging $1,200–$1,500 for partial repairs (spark plugs, coils, water pump, gaskets) that fail to resolve the underlying defect. Ford TSBs recommend long-block replacement; some dealers offer modified/corrected engines or remanufactured units. Parts availability has been constrained, with owner reports of 8–16+ week waits for replacement engines.
Recalls/TSBs owners mention: Ford issued Technical Service Bulletins 19-2139, 19-2346, 20-2100, 22-2134, and 22-2322 documenting the issue. A recall (23E03) exists for some 1.5L models (2014–2019 range); 2.0L EcoBoost models are inconsistently covered, with many 2016 units excluded by VIN/build plant despite identical symptoms. Ford Customer Satisfaction Program 19N05 does not include all affected VINs. Owners report Ford denying warranty claims citing 'improper maintenance' or 'out of warranty' status, even when vehicles have been meticulously maintained. Some owners report Ford offering partial assistance after corporate intervention or proof of design defect; others receive refusals or referral to NHTSA hotline.
Misfire and ignition system false diagnosis loop
Owners repeatedly replace spark plugs and ignition coils based on misfire codes (typically cylinder 2, 3, or 4), only to have the check engine light return within days or weeks. Repeated part replacement ($500–$700+ per visit) fails to resolve the underlying coolant intrusion, creating a costly diagnostic cycle that masks the true engine block defect.
When: Can begin within weeks of initial misfire code; owners report multiple replacement cycles over weeks to months before coolant intrusion is identified
Symptoms owners cite: Intermittent check engine light with misfire codes; Rough idle or hesitation; Light goes out after code reset, then reappears shortly after; No improvement after spark plug/coil replacement
Codes mentioned: P0301, P0302, P0304
Repairs/costs cited: Owners spent $500–$700 per visit replacing spark plugs and ignition coils; some shops replaced coils/plugs multiple times before diagnosing coolant leak. One owner replaced all four spark plugs twice within weeks.
Recalls/TSBs owners mention: Independent shops and some dealerships recognized the pattern and escalated diagnosis to coolant intrusion. Firestone and independent mechanics identified the design flaw; Ford dealerships initially misdiagnosed or recommended head gasket replacement ($3,000+) before corporate involvement revealed the true defect.
Sudden engine stalling and loss of power on roadway
Engine suddenly loses power or stalls without warning while driving at highway or city speeds, creating immediate collision risk. Vehicle may coast to shoulder but is inoperative until cooled and restarted. Check engine light often comes on only after stalling occurs. Event can occur with no prior warning signs.
When: Can occur suddenly; some owners had no warning lights prior to stall. Events reported as single incidents or recurring (2–4+ occurrences per owner)
Symptoms owners cite: Sudden loss of engine power while driving; Engine stalls mid-drive or on acceleration; Vehicle cannot exceed 10–20 MPH after restart; Check engine light may appear during or after event; Vehicle may need to cool before restarting successfully; Vehicle may require multiple restart attempts
Codes mentioned: P0301, P0302, P0304, P2111, P2112
Repairs/costs cited: Some owners report throttle body replacement ($400+ in one case) for stalling related to P2111/P2112 codes; however, many stalling events traced back to coolant intrusion causing engine shutdown. One owner spent $700 on fuel system and engine flush before stalling recurred.
Recalls/TSBs owners mention: Some repairs involved throttle body replacement per dealer work orders; others involved long-block engine replacement after coolant intrusion diagnosis. No preventive recalls or systematic TSB-based service campaigns identified in narratives.
Throttle body and electronic control issues
Vehicle experiences limp-mode operation, loss of acceleration response, or inability to control idle/throttle. Check engine light displays P2111 (throttle control circuit stuck open) or P2112 (stuck closed). Dealers replace throttle bodies; symptoms sometimes persist or recur, suggesting underlying fuel system or engine control issues.
When: Can occur early in ownership or after several years; one complaint noted at 10,500 miles
Symptoms owners cite: Check engine light with P2111 or P2112 codes; Sudden loss of power on acceleration; Vehicle enters limp mode (reduced power); Accelerator pedal unresponsive or delayed response; Engine stalls on light throttle application; RPM drop to under 500 with no throttle response
Repairs/costs cited: Throttle body replacement cost reported at approximately $400+ (dealer diagnosis and repair). One owner replaced throttle body and later had transmission issues diagnosed; repair took 6+ days at dealership.
Recalls/TSBs owners mention: Dealer verified issue and replaced throttle body per technical service procedure; however, underlying causes may relate to fuel system or coolant intrusion affecting sensor performance.
Intermittent engine shutdown and restart loop with 'not in park' message (hybrid models only)
On hybrid 2016 Fusion models, engine stalls unexpectedly while driving at various speeds. Dashboard displays misleading 'your car is not in park' message despite vehicle being in drive. Engine restarts after driver coasts to shoulder, but risk of collision or transmission damage is high. Recurs multiple times with no clear error codes.
When: Multiple incidents reported over span of weeks; most recent incident date provided
Symptoms owners cite: Engine stalls while driving at 35–70 MPH; False 'not in park' message on dashboard; No acceleration during stall event; Vehicle restarts after coasting to shoulder; Failure to diagnose after dealer inspection
Repairs/costs cited: No repairs completed; owner reports dealer inability to reproduce issue or find diagnostic codes
Recalls/TSBs owners mention: No specific recall or TSB identified in narrative for this symptom pattern; owner referred to NHTSA
Transmission rebuild/replacement requirement (secondary to coolant intrusion)
Some owners experienced transmission issues (rebuild or replacement) coinciding with or following coolant intrusion diagnosis. One owner's transmission was recommended for replacement after engine coolant issues began; unclear if coolant contamination of transmission fluid or separate defect.
When: Reported in one case after months of coolant overheating warnings
Symptoms owners cite: Transmission slipping or failure to accelerate above low speed; Warning message for transmission service; Vehicle unable to shift properly after engine coolant issues
Repairs/costs cited: Transmission rebuild/replacement estimated at undisclosed cost; one owner reported $1,175.98 in subsequent repair costs for ignition coils, fluids, and oil filter, followed by serpentine belt and fuel throttle service at $683.79
Recalls/TSBs owners mention: Dealership recommended transmission work; unclear if covered under any recall or warranty
Engine startup failure and no-crank conditions
Vehicle fails to start or turn over, sometimes preceded by rough starting behavior. Affects even low-mileage vehicles purchased new or used. Some owners report intermittent no-crank over weeks; others experience total failure after coolant intrusion diagnosis.
When: Can occur within first weeks of ownership or after months of use
Symptoms owners cite: Engine does not crank on startup; Rough starting followed by complete failure to start; High resistance in battery terminals (misdiagnosis in one case); Unable to start after coolant intrusion develops
Repairs/costs cited: One owner reported $400 charge for battery terminal corrosion cleaning (later determined to be unrelated); multiple tow truck calls and service visits without resolution
Recalls/TSBs owners mention: Ford dealership initially misdiagnosed as high-resistance battery terminal; no recall or TSB identified for no-crank condition in low-mileage vehicles
Synthesized from 446 NHTSA owner complaints — unverified consumer allegations, summarized for patterns. The verbatim filings appear below.
What owners are reporting 9 most recent
Two days ago on 12/29/22 I noticed white smoke coming from tailpipe. Later that day noticed the coolant level very low. Later on that day started the vehicle and it violently shuttered for about 5 or 6 seconds after starting. This same thing had happened to my daughter the day before. On 12/30/22 was at mechanics discussing catalytic converter issue due to an alarm and he noticed the smoke. I…
Coolant is entering cylinders - known issue in the 1.5 ecoboost motors as there are recalls in the 2017 and 2018 vehicles. Ford will not rebuild motor must be replaced at a cost of $5k. Vehicle is 4 years old and just ver 100k miles. No excuse for needing a motor and also Ford is doing nothing to help the customer. Safety issue is mine lost power going up a hill and stopped me in the middle of…
The car reads as a 4th cylinder misfire but it's not. The coil has been replaced twice and the spark plugs have been replaced twice also. Went back to Ford after spending all this money to tell me there is a leak going into my engine form my coolant. Now I have to get a new whole engine and I only have the car for about 3-4 years. This is about a $5,000-$6,000 fix. After researching, this should…
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…
Flex Plates in Ford Fusions with EcoBoost engines are continuously breaking. They have a recall issued for Ford Edge 2016 with the same engine as Ford Fusion 2016 but none for the Fire Fusion. Once these break you can lose power while driving which can be extremely dangerous if on a highway. There is clearly an issue with the flex plates used and a recall should be issued to fix these.
Coolant leak into cylinder 3 due to defective 2.0L Ecoboost engine. Requires complete engine replacement.
I took my 2016 Fusion in to have the timing belt changed after crossing the recommended 125,000 miles. I received a call from the head mechanic telling me that they had halted all work due to evidence of coolant leaking into the engine. He told me that this was a common defect/design flaw found in these cars that Ford has yet to issue a recall on. He then quoted me an exorbitant number for…
Driving on highway and car had serious misfire stalling the engine. No lights or warnings prior. Upon inspection number 1 cylinder has near zero compression.
The contact owns a 2016 Ford Fusion. The contact stated while driving at 55 MPH, the accelerator pedal was depressed however, the vehicle failed to properly respond. The check engine warning light was illuminated. The vehicle was taken to an independent mechanic and the spark plugs were replaced; however, the failure persisted. The vehicle was then taken to the dealer and the contact was informed…
Had engine trouble with your 2016 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 2016 Ford Fusion?
It's a documented issue but not catastrophic. 446 complaints have been filed. Repairs average $3,100 and most owners catch it before it causes a breakdown.
At what mileage does the engine typically fail?
Across the 247 complaints that reported odometer mileage, most engine failures cluster between 67,000 and 122,000 miles, with the median around 96,000. A quarter of owners report trouble before 67,000; a quarter make it past 122,000. 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/2016/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.