Technical Service Bulletins

Coolant Leaks in Ford Fusion

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Some 2014-2017 Ford Fusion vehicles equipped with a 1.5L GTDI engine and at least 10,000 miles may exhibit a low coolant, white exhaust smoke and a MIL on. This condition may be due to an intake manifold bolt backing out, causing damage to the charge air cooler (CAC).

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FUSION COOLANT LEAK

Some 2014-2017 Ford Fusion vehicles equipped with a 1.5L GTDI engine and an odometer reading 10,000 miles or above may exhibit a low coolant, white exhaust smoke and a MIL on, with DTCs P0217, P0300. P0301, P0302, P0303, P0304, P0316 and/or P1299. This condition may be due to an intake manifold bolt backing out, causing damage to the charge air cooler (CAC).

  1. Check engine coolant level. If low, connect the Ford integrated diagnostic system (IDS) or Ford J2534 diagnostic software to the data link connector and check for DTCs.
  2. If any of the above DTCs are found, pressure test the cooling system. 
  3. If pressure does not remain constant for 5 minutes, disconnect the throttle body inlet pipe from the throttle body and position aside. Disconnect the charge air temperature sensor. Loosen both clamps and remove the inlet pipe to throttle body rubber pipe connector.
  4. Inspect the inside of the intake manifold. The appearance of a liquid-like engine oil may be observed in the bottom of the intake manifold, which may be as deep as ½-inch. This is a normal function of the intake manifold and PCV system.
  5. If coolant is found inside the intake manifold, replace the intake manifold and CAC assembly.


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