Skip to content
MotorFiable

Ford cars

Ford Fusion problems (2002–2012)

The only engine of the Ford Fusion that we have documented, the 1.4 HDi, has high or critical severity faults in the versions it is fitted to. Our verdict for the version it is fitted to: «With caution».[1][2]

Outside the engine: Outside the engine, according to owner reports collected by fiches-auto.fr (206), the Fusion stands out for the clutch and manual gearbox, rear suspension, wheel bearings and alternator; we have found no recalls or independent studies.[3][4]

Ford Fusion (2002–2012)
Photo: Rudolf Stricker · CC BY-SA 3.0 · Wikimedia Commons. Reference image for this generation.
02468106.6out of 10

Ford Fusion rating: acceptable reliability

Calculated using only 10 documented faults and their sources: the most serious and frequent faults weigh more. Limited evidence: it is based on few sources or few documented faults, so it is not included in the rankings. Having few documented faults does not mean it is reliable: it may simply be little studied. How it is calculated

  • Engine5.75 faults
  • Gearbox8.61 fault
  • Suspension7.22 faults and ITV (technical inspection)
  • Brakes8.5Technical inspection (ITV) only: 0.6 times the defects normal for its age
  • Tyres and wheels10.0No documented faults
  • Steering9.2Technical inspection (ITV) only: 0.3 times the defects normal for its age
  • Electrical system8.61 fault
  • Headlights and lights7.0Technical inspection (ITV) only: 1.2 times the defects normal for its age
  • Electronics and infotainment10.0No documented faults
  • Climate control10.0No documented faults
  • Bodywork and interior9.21 fault and ITV (technical inspection)
  • Airbags and safety10.0No documented faults

The weak points of the Ford Fusion

  1. 1Medium severity: Injectors that lose their seal and let diesel escape1.4 HDi engine
  2. 2High severity: Timing belt and water pump1.4 HDi engine
  3. 3Medium severity: Premature turbo wear from poor lubrication1.4 HDi engine
  4. 4Medium severity: EGR valve clogged with carbon1.4 HDi engine
  5. 5Medium severity: Clutch wear and Durashift manual gearbox faultsGearbox and clutch

Documented engine

The first label is the most serious fault affecting that engine in this car; the second, our verdict for the versions it is fitted to. Each engine's risk index is calculated only from the faults that affect this car (how we calculate it). We only show engines we have documented with sources: if yours does not appear, we have not analysed it yet. View all engines

See what to check before buying

Outside the engine

6 sourcesHow we work

1.4 HDi

PSA/Ford 1.4 HDi and TDCi (DV4TD) · Diesel

In the Fusion
2002–2012[5][6]
Name
1.4 TDCi 68
Faults that affect it
5 · 1 of high or critical severity
Risk index on this car
43
Moderate risk

Verdict for the version it uses

  • 1.4 HDi/TDCi 54/68/70 8V (DV4TD, 2001-2009)2001–2009 · 54–70 hp · DV4TD, 8HT, 8HX, 8HZ

    With caution

    It shares the injector fragility of the rest of the family, documented in both the 68 and 70 hp versions, along with occasional turbo and EGR valve failures. It is worth buying with a maintenance history and no noticeable diesel leaks.[1][2]

Faults that affect the Fusion

  1. Medium severityFrequency: Very frequentInjectionInjectors that lose their seal and let diesel escapeThe most cited weak point of the 1.4 HDi is its injectors: over time they can lose their seal and let diesel escape, which is usually noticed as a smell of diesel in the car. It appears in the two most common outputs (68 and 70 hp) and in both cases it is identified as the engine's main weakness.
  2. High severityFrequency: OccasionalTimingTiming belt and water pumpThe 1.4 HDi uses a timing belt (with an additional short chain on the 16-valve version), and Fiches-Auto documents some of its failures, along with the water pump, at around 100,000 km. We have not found the manufacturer's official change interval in a reliable source.
  3. Medium severityFrequency: OccasionalTurboPremature turbo wear from poor lubricationThe BorgWarner KP35 turbo of the 8-valve version can wear out early when the oil degrades and forms carbon deposits, reducing its lubrication. It is a minority but recurring fault: it appears in just over 9% of the reports collected for the 68 hp version.
  4. Medium severityFrequency: OccasionalEmissions controlEGR valve clogged with carbonThe EGR valve, which recirculates part of the exhaust gases to reduce emissions, can seize or clog up with the carbon those gases carry. It appears in a noticeable minority of the reports collected for the 68 hp version.
  5. Medium severityFrequency: RareTimingCrankshaft damper pulley wearThe crankshaft pulley incorporates a rubber ring that dampens engine vibrations and that can lose grip or crack over time. We have found only one specific report of this fault (a Peugeot 206 at around 250,000 km), so we do not consider it a widespread fault.

Fusion 1.4 HDi pageAll versions and faults of the 1.4 HDi

Faults of the Ford Fusion outside the engine

Suspension, brakes, tyres, electronics and the rest of the car. They occur with any engine.

What the MOT inspection finds on the Ford Fusion

Official Dutch MOT (APK) inspection data: 4,660 inspections of 1,555 cars registered between 2002 and 2012, compared with cars of the same age.

  • Suspension and axles· counts in the score

    Defects in 13.2% of inspections; in cars of its age, 9.5%.

    More defects than average

  • Brakes· counts in the score

    Defects in 6.4% of inspections; in cars of its age, 10.9%.

    Fewer defects than average

  • Steering· counts in the score

    Defects in 1% of inspections; in cars of its age, 3.7%.

    Fewer defects than average

  • Headlights and lights· counts in the score

    Defects in 32.3% of inspections; in cars of its age, 27.1%.

    Average

  • Rust and bodywork· counts in the score

    Defects in 0.5% of inspections; in cars of its age, 1.4%.

    Fewer defects than average

  • Exhaust and emissions

    Defects in 2.4% of inspections; in cars of its age, 5.3%.

    Fewer defects than average

  • Fluid leaks

    Defects in 5.9% of inspections; in cars of its age, 10.2%.

    Fewer defects than average

  • Glass, wipers and mirrors

    Defects in 7.5% of inspections; in cars of its age, 5.9%.

    More defects than average

  • Tyres and wheels· depends mostly on maintenance

    Defects in 17.3% of inspections; in cars of its age, 17.5%.

    Average

The inspection measures wear and the defects visible at a periodic check, not engine or electronics failures. Source: RDW Open Data (public domain). How we calculate it · opendata.rdw.nl

Checklist for buying a used Ford Fusion

Check the advert or the paperwork to see which engine the car has and go through its section. Each point comes from a documented fault; you can tick them off as you inspect.

If it has the 1.4 HDi (2002–2012)

Injectors that lose their seal and let diesel escape

Medium severity

Timing belt and water pump

High severity

Premature turbo wear from poor lubrication

Medium severity

EGR valve clogged with carbon

Medium severity

Crankshaft damper pulley wear

Medium severity

Wear parts for the Ford Fusion

Brakes, wiper blades, pollen filter and battery, searched for this model. The exact part number depends on the engine and year: confirm it with the registration plate or VIN.

Affiliate links: if you buy from these shops, MotorFiable may receive a commission at no cost to you. Check compatibility against the registration plate or VIN before ordering. Affiliate links

Buying a Ford Fusion?

We will put you in touch with a partner only if you authorise it in the form.

Own a Ford Fusion? Tell us what faults you have had, at what mileage and how much you paid. Report your fault.

Frequently asked questions

Is the Ford Fusion reliable?

The only engine of the Ford Fusion that we have documented, the 1.4 HDi, has high or critical severity faults in the versions it is fitted to. Our verdict for the version it is fitted to: «With caution». Outside the engine, according to owner reports collected by fiches-auto.fr (206), the Fusion stands out for the clutch and manual gearbox, rear suspension, wheel bearings and alternator; we have found no recalls or independent studies.

What problems does the Ford Fusion have apart from the engine?

Outside the engine, according to owner reports collected by fiches-auto.fr (206), the Fusion stands out for the clutch and manual gearbox, rear suspension, wheel bearings and alternator; we have found no recalls or independent studies. The most important documented faults are: clutch wear and Durashift manual gearbox faults (gearbox and clutch, medium severity), shock absorber wear and broken rear springs (suspension, medium severity), premature wheel bearing wear (suspension, medium severity) and premature alternator failure (electrical system, medium severity).[3][4]

What faults does the Ford Fusion have?

The most important by severity and frequency, on the engines we have documented, are: injectors that lose their seal and let diesel escape (1.4 HDi, medium severity), timing belt and water pump (1.4 HDi, high severity), premature turbo wear from poor lubrication (1.4 HDi, medium severity), EGR valve clogged with carbon (1.4 HDi, medium severity) and crankshaft damper pulley wear (1.4 HDi, medium severity).

Sources

Every fact on this page links to its source. If you find an error, let us know.

  1. Essai, avis et fiabilité des 1.4 HDI 68 chFiches-Auto.fr · Motoring press · consulted 27 September 2026 · in French
  2. Essai, avis et fiabilité des 1.4 HDI 70 chFiches-Auto.fr · Motoring press · consulted 27 September 2026 · in French
  3. Tous les problèmes sur Ford FUSION 2002-2008 (206 témoignages)fiches-auto.fr · Other source · consulted 5 October 2026 · in French
  4. Ford Fusion (Europe)Wikipedia · Other source · consulted 5 October 2026
  5. Ford Duratorq engineWikipedia (en) · Other source · consulted 27 September 2026
  6. Ford Fusion (Europa)Wikipedia (es) · Other source · consulted 27 September 2026 · in Spanish