Ford Fusion
203 kW 2.0L EcoBoost in the Mondeo BA7. Powerful unit, shares all typical 2.0 EcoBoost weaknesses. In the Mondeo context often high-mileage with frequent motorway use.
Fusion 2.0L EcoBoost — Mondeo for America
Same platform as Mondeo V. Solid midsize, MyFord Touch freezes, discontinued without replacement in 2020.
Engine Weaknesses 6
The in-tank low-pressure fuel pump is a known weak point on all 2.0 EcoBoost engines. A clogged fuel filter increases pump load until failure.
Symptoms: Hesitation and power loss under load, difficult starting, code P0087, sudden engine stall.
Older 2.0 EcoBoost engines show hairline cracks in the open-deck block at high mileages with coolant intrusion. Issue existed until approximately 2019; revised block is more robust.
Symptoms: Coolant loss with no visible leak, rough cold start, oil-coolant mix.
Known manufacturing defect up to mid-2019: hairline cracks in the cylinder block between cylinders allow coolant to enter the combustion chamber. Ford revised the block from mid-2019 onwards.
Symptoms: Coolant loss with no external leak; rough cold start; white smoke from exhaust; milky coolant.
The boost control solenoid or wastegate can cause boost pressure instability. Code P0299 (turbo underboost) is frequently documented, particularly at higher mileages.
Symptoms: Code P0299, noticeable power drop on acceleration, check engine light.
The 2.0 EcoBoost uses direct injection only, so crankcase oil mist deposits carbon on the intake valves. Cleaning every 60,000–80,000 km recommended.
Symptoms: Power loss in the mid-rev range; increased fuel consumption; hesitation at 2,000–3,000 rpm; rough idle.
Direct injection leads to carbon deposits on the intake valves. Without port injection, deposits accumulate year on year and measurably reduce flow cross-section.
Symptoms: Stumble on cold start, reduced acceleration, slightly increased fuel consumption from around 80,000 km.
Vehicle Weaknesses 7
EPS temporarily loses assist — safety concern. NHTSA investigation for 2013-2014.
The PowerShift automatic is problematic in the MK5 as well. From 60,000 km typical symptoms: judder, shift hesitation, unexpected gear skipping. Gearbox oil change every 50,000–60,000 km.
Early 1.5 EcoBoost variants of the Mondeo Mk5 developed hairline cracks in the cylinder block, causing coolant loss and in extreme cases total engine failure. Ford only resolved the underlying problem with the redesigned block from mid-2019.
After 8-10 years in salt belt: rear wheel arches start rusting.
Due to the high vehicle weight, springs, dampers and suspension joints wear faster than on the predecessor. MOT testers flag axle components more frequently from 100,000 km.
Brake discs and pads wear noticeably faster on the MK5 than on its predecessor, partly due to the higher vehicle weight. Complete replacement costs are higher than expected.
SYNC 2/MyFord Touch: frequent freezing and reboots. 2013-2016 worst affected.
