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2016 Ford Fusion Fuel System Problems

39 owner-reported fuel system complaints from NHTSA data

39
Complaints
1
Recalls
1
Crashes
Jan 2018Dec 2020
Date Range

Data sourced from NHTSA public database. For informational purposes only. Always consult a qualified mechanic.

Fuel System Recalls (1)

RECALLCampaign #15V618000

FUEL SYSTEM, GASOLINE:STORAGE

Ford Motor Company (Ford) is recalling certain model year 2016 Ford Fusion vehicles manufactured September 3, 2015, to September 13, 2015, and 2016 Lincoln MKZ vehicles manufactured September 3, 2015, to September 12, 2015. The affected vehicles have a fuel tank that may have insufficent wall thickness. As a result, the fuel tanks may crack in the event of a crash and thus the vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 301, "Fuel System Integrity."

Fix: Ford will notify owners, and dealers will replace the fuel tank, free of charge. The recall began on October 19, 2015. Owners may contact Ford customer service at 1-866-436-7332. Ford's number for this recall is 15C11.

Owner Complaints (39)

criticalFUEL/PROPULSION SYSTEM
Filed: Oct 2025

EVAP blocking valve failed and car immediately went into limp mode on the highway. By doing this it could cause a crash. EVAP blocking valve also should last the life of the vehicle.

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NHTSA #: 11696645
criticalFUEL/PROPULSION SYSTEM
Filed: Apr 2023

After a rear-end collision, my check engine light came on. I have been told it is due to a problem with the purge valve; however, the purge value is located in the front of the vehicle.

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NHTSA #: 11517909
criticalFUEL/PROPULSION SYSTEM
Filed: Jul 2022

When the car is going down the highway it will make a loud sound and the just shut off in the middle of traffic and some time it will not make a.sound,and it shuts off. This is a very dangerous thing to be happening on a highway. I have had several close call in which the person or people behind me had to swirl around me to keep from causing a major car crash.

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NHTSA #: 11473079
criticalFUEL SYSTEM, GASOLINE
Filed: Aug 2021

throttle body-wpc part ds7z9e926d The throttle control element failed.

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NHTSA #: 11431267
criticalFUEL/PROPULSION SYSTEM
Filed: Mar 2018

We've been experiencing the swishing movement of the the gas in the gas tank when braking, going over a rugged surface & going over speed bumps or potholes. Some times there is a strong smell of gas from inside the car to the point where we have to put the windows down. We've taken the car to 2 separate ford services & neither has been able to remedy the issue.

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NHTSA #: 11081199
criticalFUEL/PROPULSION SYSTEM
CrashFiled: Jan 2018

I was driving slowly up a small slight hill, made a right turn, then another quick right turn to drive straight into a parking spot located in a condo parking lot and took my foot off the gas to put it on the brake. I was probably going 2 to 3 MPH. A person could have outwalked the car.

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NHTSA #: 11061639
criticalFUEL/PROPULSION SYSTEM
Filed: Jun 2016

Car hesitates when accelerating from coast, generally in the 40-50 MPH range, but at other times as well. This issue has caused near-accidents in heavy traffic when one expects the vehicle to accelerate but instead feels as if it's about to stall. This is especially dangerous when entering and exiting freeways when predictable acceleration is needed.

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NHTSA #: 10875727
criticalFUEL/PROPULSION SYSTEM
Filed: May 2016

The subject car of this report is an enterprise rental car rented in peoria, illinois. On thursday, may 5, 2016, my wife and I were traveling eastbound on i74 at milepost 166 in indiana. I was in the passing lane at 75 MPH, closely followed by a tractor-trailer semi, and we were passing two other tractor-trailer semis in the adjacent lane.

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NHTSA #: 10870218
highFUEL SYSTEM, GASOLINE
Filed: Mar 2025

The contact owns a 2016 Ford Fusion. The contact stated that while the vehicle was stopped, the engine started to rev. There was no warning light illuminated.

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NHTSA #: 11648088
highFUEL/PROPULSION SYSTEM
Filed: Apr 2024

Vehicle after every single time we refuel have to press gas pedal to start afterwards it keeps stalling until you gun the acceleration to pick up speed. Vehicle after that runs okay until the next time you fuel up.

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NHTSA #: 11584782
highFUEL/PROPULSION SYSTEM
Filed: Jun 2022

The car stalls on idle repently and check engine light won't turn on, so there no error codes. But apparently it's a fuel pressure sensor.

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NHTSA #: 11467909
highFUEL SYSTEM, GASOLINE
Filed: Mar 2022

The contact owns a 2016 Ford Fusion. The contact stated while driving at an undisclosed speed with the fuel tank half-full, the vehicle stalled inadvertently. Additionally, the contact stated that the failure reoccurred after refueling the vehicle.

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NHTSA #: 11458144
highFUEL SYSTEM, GASOLINE
Filed: May 2021

Canister purge valve malfunction. I had trouble starting my car a couple of times and it would randomly stall out. But after getting gas this last time, I noticed a humming/grinding sound coming from the gas tank.

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NHTSA #: 11417810
highFUEL/PROPULSION SYSTEM
Filed: Dec 2020

Canister purge valve malfunction. Car stalled completely and would not start back up. Thankfully this happened when I was driving slow in a parking lot and not on the busy freeway.

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NHTSA #: 11377265
highFUEL/PROPULSION SYSTEM
Filed: Oct 2019

I found a fuel leak on my 2016 ford fusion titanium ecoboost. About 5 months ago when I first notice the problem, a smell of fuel on the left rear passenger side door and as you go further to the rear,the smell of fuel gets stronger, I went to the ground to check for any sign of leaks but I never found any, except for the strong scent of fuel.

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NHTSA #: 11268762
highFUEL/PROPULSION SYSTEM
Filed: Sep 2018

My car would stall right after I get gas! Then after that the check engine light came on and the car is idling down. Took it to to be placed on a machine and it's reading a purge valve malfunctioning.

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NHTSA #: 11129766
highFUEL/PROPULSION SYSTEM
Filed: Jul 2018

The car will stall when coming to a stop and only at low speeds when coming to a stop. Never while driving the fuel filler flapper will vibrate making a what sounds like a growl. Try to restart it will run fruff and die.

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NHTSA #: 11110460
highFUEL/PROPULSION SYSTEM
Filed: Jul 2016

Car started stalling randomly while coming to a stop in city traffic. Car has now escalated to stalling while driving on highway, sudden power loss, including power brakes and steering.

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NHTSA #: 10884971
mediumFUEL/PROPULSION SYSTEM
Filed: Jan 2025

For 2 1/2 months, every time I pump gas, I couldn't get the car to start without revving the engine. I took it to the Ford service center, and they informed me that it's the Canister Purge Valve that needed to be replaced. They also mentioned that they have seen a lot of cars with the same issue.

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NHTSA #: 11639562
mediumFUEL SYSTEM, GASOLINE
Filed: Mar 2024

The contact owns a 2016 Ford Fusion. The contact stated that upon refueling the vehicle, the check engine warning light illuminated on the instrument panel. After restarting the vehicle, the vehicle returned to normal functionality, but the failure became a regular occurrence.

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NHTSA #: 11579286
mediumFUEL/PROPULSION SYSTEM
Filed: Jan 2024

The canister purge valve in this vehicle repeatedly goes bad. Since buying the vehicle in 2018, the purge valve went bad in 2019, twice in 2020 and last (although I’m sure it will happen again) 2024. It throws the check engine light on and will just about die everytime putting gas into the car or when stopped for random periods of time.

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NHTSA #: 11565029
mediumFUEL/PROPULSION SYSTEM
Filed: Sep 2022

Purge valve, fuel filler neck/vacuum neck and air grill issues - check engine lights on for engine and inject issues.

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NHTSA #: 11485905
mediumFUEL/PROPULSION SYSTEM
Filed: Aug 2020

The car started missing like thr transmission was going out til it completely stopped running. Finally had the transmission replaced and it did it again. The tappet on the high pressure fuel pump under the hood ended up being the problem.

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NHTSA #: 11343861
mediumFUEL/PROPULSION SYSTEM
Filed: Jul 2020

While driving on the highway, the car suddenly displayed a 'wrench' indicator which states 'see owner's manual'. The car lost the ability to accelerate (gas pedal/acceleration was disabled). After steering the vehicle to the side of the road, the car began to idle very rough before the car was turned off.

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NHTSA #: 11341923
mediumFUEL/PROPULSION SYSTEM,UNKNOWN OR OTHER
Filed: May 2020

About a year ago the vehicle would just stop for no reason. The check engine light would come on occasionally and it said it was the fuel sensor. Sometimes the car would completely shut down when accelerating or at highway speeds.

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NHTSA #: 11326361
mediumFUEL SYSTEM, GASOLINE
Filed: May 2020

I bought the care in april 2017,within a moth I started smell car outside the car when ever I started it. You car smell it up to 75 ft away. Towards the front and drivers side.

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NHTSA #: 11325532
mediumFUEL/PROPULSION SYSTEM
Filed: Mar 2020

We bought our ford fusion se in august 2019 and now we're told our purge valve needs to be replaced and it isn't covered by warranty. Our check engine light came on when driving on the interstate and we made an appointment immediately to be seen.

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NHTSA #: 11317224
mediumFUEL/PROPULSION SYSTEM
Filed: Jan 2020

Evap fuel vapor canister purge valve assembly failed. Dealer charging $314.00 and said ford does not cover this part under warranty. This is an emission component with many comments about known failure.

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NHTSA #: 11300794
mediumFUEL/PROPULSION SYSTEM
Filed: Sep 2019

While driving down the freeway at 70 MPH all of a sudden had a loss of throttle service wrench light, airbag light, see owners manual lit up happened in an area where there was nowhere to pull off the freeway very unsafe heard of a recall that had happened for a throttle body issue that I never received notice for car mileage currently around 60, 500 miles ford fusion se have a known issue with this among other ford products is it going to take someone to get killed in order for a recall to be reordered talk to the dealer and they are not willing to help me told me that I have to pay for all of the stuff out of pocket.

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NHTSA #: 11253765
mediumFUEL/PROPULSION SYSTEM
Filed: Jan 2019

When filling gas tank it seems to have air in the tank. Sometimes after filling the car won't start for a couple minutes and when it does, it sputters like it will cut off, but after you get it running it's okay. Also, you can never get the same full tank distance, it will vary each fill up with the same fuel economy with each fill up.

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NHTSA #: 11170427
mediumFUEL/PROPULSION SYSTEM
Filed: Nov 2018

Car dies while driving on city street or exiting freeway. Cause unknown. Driving the ford fusion titanium on city streets results in the car dying while in motion as the speed slows, for instance to make a right or left turn onto another street.

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NHTSA #: 11153256
mediumFUEL/PROPULSION SYSTEM
Filed: Feb 2017

My car had been vibrating pretty bad for a while, but I live on a dirt road and know that mud can cause this, so I chalked it up to that and was getting the under carriage washed and noticing that this did not help.

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NHTSA #: 10956230
mediumFUEL/PROPULSION SYSTEM
Filed: Aug 2016

Throttle body failed and had to be replaced only after 13,500 miles, purchased this vehicle as brand new and is only 9 months old. The vehicle died multiple times on the highway and could have got me in a serious wreck. The ford tech said they are replacing hundreds of these yet I was never notified of it being a possible issue that I could have been seriously hurt.

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NHTSA #: 10898034
lowFUEL/PROPULSION SYSTEM
Filed: Nov 2024

1st incident (Oct. 8, 2024)- while traveling up a slight incline vehicle began to sputter and then stopped accelerating. No codes where thrown, no warning of any kind.

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NHTSA #: 11626482
lowFUEL/PROPULSION SYSTEM
Filed: Sep 2021

Driving on internet highway at approximate 65 MPH, the car shut off. I coasted to the roadside in heavy traffic. after many tries, the car restarted and got off the thruway and drove home.

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NHTSA #: 11433098
lowFUEL SYSTEM, GASOLINE,UNKNOWN OR OTHER
Filed: May 2020

The high pressure fuel pump and sensor went bad after 81000 miles. The car had a whining sound when the gas pedal was depressed. The car sputtered while accelerating.

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NHTSA #: 11326455
lowFUEL/PROPULSION SYSTEM
Filed: Mar 2019

I'm losing has very fast

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NHTSA #: 11190446
lowFUEL/PROPULSION SYSTEM
Filed: Nov 2018

Car repeatedly dies after driving about 4-10 miles after first starting. Has died on me while at busy intersection (middle of it!) and has died by train tracks! Also died while merging onto interstate, has also died while driving on interstate.

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NHTSA #: 11152647
lowFUEL/PROPULSION SYSTEM
Filed: Oct 2017

After putting my car in reverse I put it in drive and it hesitates for about 4 minutes before moving into drive. This happens no matter what I am driving on.....

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NHTSA #: 11040897

Other 2016 Ford Fusion Issues