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…
2016 Ford Fusion engine problems
moderate 441 complaints filed with NHTSA · avg repair $3,100 · see engine across all vehicles →
Failure mileage
Complaints
441
Recalls
0
Avg fix
$3,100
1crash
1fire
1injury
When does it fail?
Of the 441 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 — 441.
Owners have filed 441 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.
What owners are reporting 9 most recent
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. 441 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 245 complaints that reported odometer mileage, most engine failures cluster between 67,000 and 121,761 miles, with the median around 96,000. A quarter of owners report trouble before 67,000; a quarter make it past 121,761. 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.