Ford Fusion Fuel System Problems

Fuel System complaints by model year

Which parts fail

• Storage › Evaporative emissions › Canister
  12
• Storage › Tank assembly
  7
• Delivery › Fuel pump
  4
• Storage › Evaporative emissions › Hoses/valves/sensors
  4
• Kinetic › Flywheel,bearings
  4
• Fuel injection system › Throttlebody/manifold
  3
• Storage › Tank assembly › Filler pipe and cap
  2
• Inverter
  1

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

Mileage when the problem started

• Under 25k
  12510%
• 25k–50k
  33026%
• 50k–75k
  37630%
• 75k–100k
  20016%
• 100k–150k
  15713%
• 150k+
  585%

What owners report

The contact owns a 2020 Ford Fusion. The contact stated while driving approximately 55 MPH, the contact became aware that the vehicle was losing motive power. The contact stated that the RPM was fluctuating. The contact stated that the check engine warning light was illuminated. The contact stated that the vehicle stalled but was able to be restarted. The contact stated that the failure had occurred three other times. The contact had taken the vehicle to a local dealer, where it was diagnosed and determined that the tube assembly fuel vapor separator (9D289) needed to be replaced. The vehicle had not been repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 102,495.

"The incident occurred immediately after shifting the vehicle into reverse and starting to move. The engine suddenly shut down with a 'System Performance' alert, and cooling fans engaged at maximum speed. Moments later, a thermal runaway event began in the high-voltage Li-ion battery pack, leading to a catastrophic fire. This is directly related to Recall 23V440 / 23S33 (BECM failure). The fire was extinguished by the local fire department in Telavi, Georgia (Country)."

The contact owns a 2019 Ford Fusion. The contact stated that while attempting to start the vehicle, the contact heard an abnormal popping sound. In addition, the contact stated that while driving at an undisclosed speed, the accelerator pedal was depressed; however, the vehicle failed to accelerate as intended. The contact stated that the vehicle decelerated unintendedly. The check engine warning light was illuminated, and the vehicle stalled. The vehicle was taken to an independent mechanic, where it was diagnosed with EVAP failure. The contact was informed that the EVAP canister needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure. The contact referenced an unknown recall with a similar description of a failure; however, the contact was informed that the VIN was not under recall. The failure mileage was approximately 130,000.

The contact owns a 2019 Ford Fusion. The contact stated that the vehicle was difficult to start after refueling. The contact stated that several attempts were needed to start the vehicle. The contact stated that the failure was a recurring failure. The contact stated that the check engine warning light was illuminated and remained constantly illuminated. The contact had taken the vehicle to an independent mechanic where it was diagnosed and determined that the canister purge valve was stuck and needed to be replaced. The vehicle was repaired. The contact researched online and became aware that the failure was a known failure; however, there was no recall on the VIN. The manufacturer was not informed of the failure. The failure mileage was approximately 66,000.

The contact owns a 2018 Ford Fusion. The contact stated while driving at an undisclosed speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic and was diagnosed with a failed EVAP purge system. The contact was informed that the EVAP purge system needed to be replaced. The vehicle was not repaired, and the failure reoccurred. The contact stated that the fuel tank made a vibrating sound before the vehicle stalled. Additionally, the contact stated that after refueling the vehicle, the vehicle failed to restart immediately. The contact stated that the vehicle restarted after several attempts. The dealer was contacted and made aware of the failure and a service appointment was scheduled. The manufacturer was made aware of the failure and a case was filed. The failure mileage was approximately 79,000.

The contact owns a 2018 Ford Fusion. The contact stated that while driving or while stopped at a traffic light, the vehicle stalled. The vehicle was sputtering while driving at various speeds. The check engine warning light was illuminated. The contact stated that after refueling, the vehicle failed to restart. The vehicle was taken to an independent mechanic, who informed the contact that the failure was due to the canister purge valve. The vehicle was taken to the local dealer, where it was diagnosed that the canister purge valve was stuck. The vehicle was not repaired. The manufacturer was contacted and opened a case. The failure mileage was approximately 113,000.

The contact owns a 2017 Ford Fusion. The contact stated that the check engine warning light was illuminated. The message to clean around the gas cap was displayed. The contact stated while driving 30 MPH, the vehicle made an abnormally loud sound and was vibrating. The contact pulled over to the side of the road. The contact noticed that the sound was coming from the fuel tank flap. The contact stated that while pushing the fuel tank flap, the contact felt a significant air pressure, and the failure ceased after the flap was closed; however, the failure recurred while the flap was not completely closed. Additionally, the contact stated that the vehicle was experiencing rough idling and the vehicle stalled while at a traffic light. The contact stated there was black smoke coming from the tailpipe. …

There is a recall on 2017 Ford Fusion's torque converter. I currently have a 2017 Ford Fusion. After inspection at a Ford service dealership, the "torque converter clutch internally failed filling the transmission filter with metal debris and starving the pump for fluid causing debris to go throughout the transmission." The problem with this, is that even though it's list as a recall for ,y specific car, the recall is not listed under my VIN number. This inspection was done on December 17, 2024. The safety of myself and children were put at risk when my car hesitated to accelerate on multiple occurrences on busy roads and intersections. The problem has been reproduced by a Ford dealer and has also been inspected by a Ford service dealership. There were no warning lights on indicating that there was a problem.

Related recalls (3)