2011 Ford Fusion Fuel System Problems

Which parts fail

• Inverter
  1
• Storage › Tank assembly › Mounting
  1
• Fuel injection system › Throttlebody/manifold
  1

Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).

Mileage when the problem started

• Under 25k
  2010%
• 25k–50k
  7638%
• 50k–75k
  6030%
• 75k–100k
  199%
• 100k–150k
  2010%
• 150k+
  73%

Owner reports

Selected complaints filed with NHTSA by 2011 Ford Fusion owners, lightly cleaned up (personal details are redacted by NHTSA).

The contact owns a 2011 Ford Fusion. The contact stated that the lug nuts and the studs had fractured and were replaced by a tire mechanic. The contact also stated that the air bag warning light was illuminated, and the message "Check the Connection of The Fuel Inlet Port" was displayed. Additionally, the contact stated that while driving 30-35 MPH, the vehicle lost power steering functionality inadvertently while making a turn into the driveway. There was no warning light illuminated. The dealer was not notified of the failure. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and informed the contact that the VIN was only included in NHTSA Campaign Number: 21V158000 (Air Bags). Additionally, the manufacturer informed the contact the recall of NHTSA Campaign Number: 15V340000 (Steering) was previously performed on the vehicle. …

The contact owns a 2011 Ford Fusion. The contact stated that an abnormal, fuel odor was coming from the vehicle. There was no warning light illuminated. The contact then noticed that while refueling the vehicle, fuel started to leak from the vehicle. The vehicle was taken to an independent mechanic who confirmed the fuel leak. Upon investigation, the contact discovered NHTSA Campaign Number: 15V793000 (Fuel System, Gasoline). The contact reached out to the manufacturer who referred her to a local dealer for a diagnostic test. The contact was informed by the dealer that additional work was needed to determine the cause of the failure, which would cost an additional fee. The vehicle was not repaired. The failure mileage was approximately 131,000.

The contact owned a 2011 Ford Fusion. The contact stated that while driving at an undisclosed speed, the vehicle stalled. Additionally, there was an abnormal gasoline odor coming from the vehicle. The check engine warning light was illuminated. The contact inspected the vehicle with a scanner and received an EVAP system error code. The vehicle was able to be restarted. The contact stated that while refueling the vehicle, there was fuel leaking from the vehicle near the fuel tank. The dealer was contacted; however, the vehicle was not diagnosed or repaired. The manufacturer was made aware of the failure. The failure mileage was approximately 158,000.

The contact owns a 2011 Ford Fusion. The contact stated that the vehicle had previously been serviced under NHTSA Campaign Number: 15V793000 (Fuel System, Gasoline) at the dealer; however, after the recall was repaired, the check engine warning light illuminated and a fuel odor was detected while driving. The vehicle was taken to an independent mechanic who diagnosed that the recall had not been performed. The vehicle was not repaired. The manufacturer was made aware of the failure but informed the contact that the recall was repaired by the dealer. The failure mileage was 103,140.

The contact owns a 2011 Ford Fusion. The contact stated that while the vehicle was being refueled, the contact heard an abnormal sound. The vehicle was started, and the check engine warning light illuminated. Additionally, the vehicle began shaking. The contact observed an abnormally strong gasoline odor. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure. The failure mileage was approximately 125,000.

The contact owns a 2011 Ford Fusion. The contact stated that the fuel tank was cracked and leaking. There were no warning lights illuminated. The vehicle was taken to the local dealer but was not diagnosed or repaired. The contact stated that the failure was related to NHTSA Campaign Number: 15V793000 (Fuel System, Gasoline). The manufacturer was not contacted. The failure mileage was approximately 130,000.

The contact owns a 2011 Ford Fusion. The contact stated that while driving at various speeds, the vehicle would suddenly shake and vibrate. The vehicle was taken to an independent mechanic who diagnosed that the electronic throttle body was faulty and needed to be replaced. The vehicle was not yet repaired. The manufacturer and local dealer were notified of the failure. The failure mileage was 138,000.

The contact owns a 2011 Ford Fusion. The contact stated that after pulling into the driveway, the check engine warning light illuminated. The contact's husband used a code reader to check the vehicle. The contact's husband replaced the purge valve canister. The contact stated that after approximately 24 hours, the check engine warning light illuminated. The contact's husband checked the vehicle and found that the purge valve canister had failed. The vehicle was not repaired. The manufacturer was made aware of the failure and referred the contact to the NHTSA Hotline to report the failure. The contact related the failure to NHTSA Campaign Number: 15V793000 (FUEL SYSTEM, GASOLINE); however, the VIN was not included. The failure mileage was unknown.

The contact's boyfriend owns a 2011 Ford Fusion. The contact stated that while driving at various speeds, the vehicle hesitated while depressing the accelerator pedal, with the check engine warning light illuminated. The vehicle was taken to an independent mechanic, who retrieved a fault code for a failure with the canister purge valve. The contact called another independent mechanic and was given an estimate for repair. The mechanic also referred the contact to Technical Service Bulletin: 15S34. The dealer was notified of the failure, and the contact was informed that the TSB did not apply to the vehicle. The manufacturer was not notified of the failure. The vehicle was not repaired. The failure mileage was unknown.

Car was purchased used at approximately 100,000 miles. While filling tank at pump, automatic shutoff on pump triggered repeatedly. It seemed vapor was backing up into the fill tube, so filling tank consisted of pressing pump then releasing once per gallon to allow vapors to disperse and repeat. Several mechanics reported working on similar cases and suggested inspecting the CPV canister. At approximately 110,000 miles, car developed a gas tank rupture. Mechanic inspected and determined that tank had burst at seam. In researching the CPV canister, discovered recall 15S34. Vin search states that this recall does not apply to this vehicle, but symptoms are identical to technical description.

Related recalls

Fuel System complaints in other Fusion years