2018 Ford Fusion

My 1.5L EcoBoost engine experienced coolant intrusion into the cylinders, a known and documented defect associated with this engine family across multiple Ford model years. Prior to the failure, the vehicle displayed symptoms consistent with internal coolant loss, including white exhaust smoke, coolant level dropping without visible external leaks, and rough running. No external coolant leak was ever identified. The vehicle was subsequently diagnosed by an independent service center, which confirmed coolant intrusion into the engine internals consistent with a head gasket or coolant jacket failure. The component is available for inspection upon request. The failure rendered the vehicle completely undriveable. The vehicle has been out of service for approximately 12 months and has not been driven since the failure occurred. The repair was quoted at approximately $12,000 for a full engine replacement, exceeding the current market value of the vehicle. Safety was put at risk due to sudden loss of engine performance and drivability while the vehicle was in use on public roads. Coolant intrusion can cause hydrolock, catastrophic engine seizure, and sudden loss of power, all of which create risk of collision, particularly at highway speeds. This failure is consistent with a well-documented defect in the 1.5L EcoBoost engine design, which has been the subject of technical service bulletins and consumer complaints regarding coolant entering the combustion chamber. The failure occurred with no prior accident, overheating event, or owner-caused damage.

Formal Complaint – 2018 Ford Fusion 1.5L EcoBoost – Engine Block Defect Statement of Issue:I am writing to report a premature engine failure on my 2018 Ford Fusion 1.5L. The vehicle is exhibiting all symptoms of the well-documented "coolant intrusion" defect described in Ford Technical Service Bulletin (TSB) 22-2222. Despite following all recommended maintenance intervals, the engine block has failed, allowing coolant to enter the combustion chamber.Observations:Confirmed coolant loss with no external leakage found via pressure test.Significant white smoke and rough idle upon cold start. Desired Resolution: Since this is a known manufacturing defect involving the engine block's cooling channels—and not a result of wear and tear—I am requesting a "Goodwill Repair" for a long-block replacement. The current TSB denial based on [8 years] is unacceptable for a known catastrophic design flaw that compromises vehicle safety.

The engine has coolant intrusion. It is available upon inspection. Safety at risk due to side effects from the intrusion such as: engine overheating, misfiring, massive coolant loss that could cause an engine fire. The problem was diagnosed as a blown head gasket, but there is evidence of coolant loss and corrosion of spark plugs etc from coolant in engine. Has not been inspected by insurance or police. Symptoms started March 2026; check engine light on showing code P0303 (misfire in cylinder 3) and code for over temperature sensor. It occasionally ran hot, rough start up, misfiring, coolant loss (without external leaks), trouble accelerating, eventual service wrench light, and sometimes flashing engine light when it misfired bad.

The contact owns a 2018 Ford Fusion. The contact stated that while driving approximately 55 MPH on the highway, the vehicle experienced a sudden loss of power steering functionality while decelerating. The vehicle jerked, and a driver assistance system warning light illuminated. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 157,017.

Coolant Intrusion after the 19B37 customer service program has been completed back in July 23rd 2020 call Ford Motor Company and told them that this service was completed to prevent the coolant intrusion and now it's intruding my car is completely disabled I can't work I bought it with all the money that I had and they said they couldn't do nothing for me they said it's past the 7 years 84,000 miles I tried indicating to them that when disrepair is update was done to the PCM it was supposed to not cause the coolant intrusion but now 6 years later it is causing it so I feel like there should cover it and they basically told me no they don't and have a good day I cannot afford to fix it it's a $6,000 job I do not have that kind of money

Coolant intrusion in cylinder 1. Confirmed by Suburban Ford of Sterling Heights, MI. Known design flaw. Can potentially cause the engine to seize, misfiring of cylinders, excessive exhaust. Codes for rich fuel mixture and cylinder misfires were found when check engine light appeared. Checked plugs and coils before a camera was put into the cylinder to confirm the coolant intrusion. Dealership and manufacturer refuse to assist with repairs even though there was a recall for certain vehicles with this exact issue.

I was driving the vehicle on the freeway when the check engine light appeared and after a few seconds the cars engine suddenly shut off. There was a loss of power steering from the lack of engine power which made it difficult for me to steer and a sudden loss of speed which made several vehicles take evasive maneuvers to avoid having an accident with my car as I merged onto the shoulder of the freeway. After getting the car home I checked the vehicles trouble codes which appeared as P0301 cylinder 1 misfire and P0302 cylinder misfire and P0300 general misfires. I noticed a lack of coolant which I refilled and started the vehicle again to see if and how it would run. The car started but ran very rough at first and white smoke started billowing out of the exhaust. After a couple of minutes I decided to drive just down the street to my local Ford service center. They called me yesterday to tell me that the 2.0L 4 cylinder Ecoboost head gasket has failed and has allowed engine coolant to pour into the cylinder 1. The engine cylinder begins to misfire causing the engine to shake and emit white smoke from the exhaust as the coolant is burned off with the fuel. We are now seeing this safety issue and complaint with many vehicles that have the same or similar engine. They say the only remedy is to replace the long block engine with one that supposedly has a "fix" to the coolant delivery system within the engine block. Knowing what I know now, I would never have considered the purchase of this vehicle. The safety issue alone makes cars with these engines a danger to the owner and the public.