Rust (rear arches, sills)
usually 100,000–300,000 km · Wear part
Signs: Bubbling paint
Fix: Rust repair
€200–800
Common faults, service intervals and costs
Ford Fusion
2002–2012
3
engines covered
16
known faults
52,182
roadworthiness tests in the statistics
5
official recalls
Enter your VIN and mileage and get a plan built for your exact engine and gearbox.
The Ford Fusion was built from 2002 to 2012.
For this generation we cover 3 engines and 16 known faults, each with the mileage range where it usually appears.
The most expensive known risk is Turbo failure (oil starvation, 16v): it usually appears at 80,000–200,000 km and costs €700–1,600 to fix.
In UK roadworthiness tests in 2024, at 100–150 thousand km this model most often failed on: lights, wipers and visibility (26.5 %), suspension (11.7 %), brakes (10.8 %). It fails less often than average on: suspension, exhaust, emissions and leaks.
Engines
| Engine | Fuel | Timing drive | Oil |
|---|---|---|---|
| 1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma) | Petrol | Belt · 150,000 km / every 120 mo | 5W-20 / 5W-30 · Ford WSS-M2C913-C / 948-B · ~3.8–4.1 L · every 15,000 km |
| 1.4 HDi / TDCi (DV4) | Diesel | Belt · 150,000 km / every 96 mo | 5W-30 / 5W-40 · PSA B71 2290 / B71 2296 · ~3.75 L · every 15,000 km |
| 1.6 HDi / TDCi / e-HDi (DV6, 8v / 16v) | Diesel | Belt · 150,000 km / every 96 mo | 5W-30 · PSA B71 2290 / Ford WSS-M2C913-C · ~3.75 L · every 15,000 km |
Faults typical of this model
Ignition switch / immobiliser
usually 120,000–250,000 km · Wear part
Signs: Intermittent no-start
Fix: Replace the switch
€80–250
Faults by engine
1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma)
Ti-VCT cam phasers / oil control valve
usually 80,000–180,000 km · Medium risk
engine codes: HWDA, HXDA, HXDB, PNDA, PNDB, IQDB
Signs: Rattle on start, rough idle, VCT codes (1.6 Ti-VCT)
Fix: Replace phasers / solenoid; correct oil
€300–800
Ignition coil pack
usually 80,000–160,000 km · Wear part
Signs: Misfire
Fix: Replace coil
€80–200
Thermostat housing leak (plastic)
usually 80,000–160,000 km · Wear part
Signs: Coolant loss
Fix: Replace housing
€100–250
Valve clearance (shims)
usually 150,000–250,000 km · Wear part
Signs: Ticking; check more often on LPG
Fix: Adjust clearances
€150–400
1.4 HDi / TDCi (DV4)
Injectors / high-pressure pump (Siemens)
usually 150,000–250,000 km · Medium risk
Signs: Hard start, smoke
Fix: Test and replace
€400–1,200
Turbo oil feed / seals
usually 150,000–250,000 km · Medium risk
Signs: Smoke, oil use
Fix: Service the turbo
€400–900
EGR valve
usually 120,000–220,000 km · Wear part
Signs: Rough idle
Fix: Clean
€100–300
1.6 HDi / TDCi / e-HDi (DV6, 8v / 16v)
Turbo failure (oil starvation, 16v)
usually 80,000–200,000 km · High risk
model years 2004–2011 only
Signs: Whistle, blue smoke, oil loss — carbon blocks the oil feed filter
Fix: Replace turbo, oil feed pipe with filter, clean the sump
€700–1,600
Injector copper seal leak → carbon build-up
usually 80,000–200,000 km · High risk
Signs: Ticking, diesel / soot smell, carbon around injectors
Fix: Replace seals early; remove carbon
€200–900
EGR valve / cooler
usually 100,000–200,000 km · Medium risk
Signs: Limp mode, power loss
Fix: Clean or replace
€200–600
Gearboxes
Manual
Clutch wear
usually 120,000–200,000 km · Medium risk
Signs: Slipping, high bite point
Fix: Replace clutch kit
€500–900
Durashift EST (automated)
Clutch actuator / hydraulic unit
usually 80,000–160,000 km · High risk
Signs: Won't select a gear, 'gearbox fault', jerky shifts
Fix: Repair or replace the actuator; clutch re-learn
€500–1,500
Clutch wear (automated)
usually 80,000–150,000 km · Medium risk
Signs: Slipping, harsh engagement
Fix: Replace clutch + re-learn
€500–1,000
Automatic 4-speed (4F27E)
4F27E solenoids / valve body
usually 100,000–200,000 km · Medium risk
Signs: Harsh 2–3 shift, slipping
Fix: Fluid change, solenoid repair
€300–1,200
Scheduled service
Intervals and typical prices for the 1.25 / 1.4 / 1.5 / 1.6 Duratec / Ti-VCT (Ford Sigma) engine. Other engines differ in oil, timing drive and some filters; the app gives the exact plan.
| Item | Interval | Typical price |
|---|---|---|
| Engine oil + oil filterEngine | every 15,000 km or every 12 months | €70–150 |
| Cabin (pollen) filterClimate | every 15,000 km or every 12 months | €15–40 |
| Brake fluidBrakes | every 24 months | €50–95 |
| A/C service (regas + desiccant)Climate | every 24 months | €70–150 |
| Air filterEngine | every 30,000 km or every 24 months | €15–45 |
| Spark plugsIgnition | every 60,000 km or every 48 months | €50–160 |
| Auxiliary (serpentine) beltEngine | every 120,000 km | €70–180 |
| Coolant replacementCooling | every 150,000 km or every 96 months | €70–150 |
| Timing belt kit + water pumpEngine | every 150,000 km or every 120 months | €450–900 |
| Manual gearbox oilTransmission | every 150,000 km | €60–130 |
| Front brake padsBrakes | usually at 30,000–60,000 km | €60–150 |
| Front brake discs + padsBrakes | usually at 60,000–120,000 km | €150–320 |
| Rear brake padsBrakes | usually at 50,000–90,000 km | €50–130 |
| Tyres (set of 4)Wheels | usually at 40,000–60,000 km | €320–700 |
| Wiper bladesBody | checked at service | €20–50 |
| 12V batteryElectrical | checked at service | €100–220 |
Roadworthiness tests by mileage
Share of tests in the United Kingdom (DVSA MOT, 2024) that this model failed because of each system. Bold red means more often and green less often than an average car of the same age and mileage. Sample: 52,182 tests.
| thousand km | 0–50 | 50–100 | 100–150 | 150–200 | 200–250 | 250+ |
|---|---|---|---|---|---|---|
| Brakes | 3.4 % | 7.0 % | 10.8 % | 14.6 % | 17.6 % | 21.4 % |
| Suspension | 2.4 % | 7.0 % | 11.7 % | 16.2 % | 20.5 % | 24.0 % |
| Steering | 0.5 % | 1.3 % | 2.8 % | 4.3 % | 4.8 % | 6.2 % |
| Tyres and wheels | 3.6 % | 4.6 % | 6.1 % | 7.1 % | 8.1 % | 8.6 % |
| Lights, wipers and visibility | 12.7 % | 19.9 % | 26.5 % | 31.2 % | 33.9 % | 37.7 % |
| Body and corrosion | 0.9 % | 2.9 % | 5.9 % | 8.6 % | 10.3 % | 12.9 % |
| Exhaust, emissions and leaks | 0.7 % | 2.2 % | 4.6 % | 7.0 % | 8.7 % | 9.8 % |
Owner complaints in the US
Which systems owners reported to the US agency NHTSA and at what mileage. Complaints are not confirmed faults and some relate to recalls. Sample: 11,959 complaints.
Official recalls
Recalls the manufacturer published in the United Kingdom for this model (5). The same recalls usually apply across Europe. Ask an authorised dealer to check by VIN whether your car is affected and whether the work has been done.
- Airbag Takata air bag inflator may rupture on deployment21/08/2020 · R/2019/156
- Suspension / axles Rear suspension bolts may fail28/02/2012 · R/2012/012
- Steering Power steering may be lost28/11/2007 · R/2007/167
- Steering Potential loss of steering control06/08/2007 · R/2007/105
- Brakes / ABS / ESP Weld seam on rear axle is not to specification07/03/2003 · R/2003/038
Sources and notes
Faults, intervals and prices are indicative and collected from public sources and owner experience; always rely on the service book and a qualified workshop. Test statistics: DVSA – Anonymised MOT tests and results, Open Government Licence v3.0. Owner complaints: NHTSA ODI (public domain). Recalls: DVSA Vehicle Safety Branch Recalls Database, OGL v3.0. Brand and model names are trademarks of their owners and are used only to describe the vehicles.
Updated 07/10/2026