FordFusion Energi2016Overview/ford/fusion-energi/2016/base/

2016 Ford Fusion Energi

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2016 Fusion Energi.

Body PASSENGER CARTransmission Automatic (S6)

The 2016 Ford Fusion Energi is a passenger car fitted with an automatic (S6) transmission and EPA fuel-economy ratings of 22/31/25 mpg, while its maintenance schedule calls for 4.3 quarts of 5W-20 engine oil. Reliability records show 1,455 owner complaints and 11 recalls for this model year, with the engine cited as the top complaint area. Against the 2013–2020 model span, the 2016 edition falls in the earlier high-complaint phase—its 1,455 reports sit below the 2013 high of 1,774 yet remain far above the 2018 low of 7—meaning it predates the sharp reduction in complaints that characterized the line’s later years.

Model year201720162015

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Engine oil capacity4.3 qtOEM · verified
Engine oil type5W-20OEM · verified
EPA fuel economy22/31/25 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 90 · 500 CCA battery. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 90 · 500 CCAOEM · verified
Tire sizeP235/45R18OEM · verified

OE service part numbers OEM · verified

BatteryBAGM48H6760
Cabin air filterDG9Z19N619D

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

TransmissionAutomatic (S6)

Dimensions & weight NHTSA vPIC

Overall length191.7 in
Overall width72.8 in
Overall height58.3 in
Wheelbase112.2 in
Curb weight3435 lb
Track (front / rear)62.6 / 62.6 in
Weight distribution (front / rear)59/41

Ratings & economy EPA / vPIC

EPA city / highway / combined22 / 31 / 25 mpg
DrivetrainAll-Wheel Drive
Passenger volume100 cu ft
Cargo volume16 cu ft
Recommended fuelRegular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

This engine holds 4.3 qt of 5W-20 engine oil, 80W-90 · GL-5 in the differential, DOT 4 brake fluid. Torque the oil drain plug to 18.0 ft-lbs. The firing order is 1-2-3-4. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Automatic Transmission Fluid Capacity4.0-6.0
Brake FluidDOT 4
Differential Gear Oil80W-90 · GL-5
Differential Gear Oil Capacity2.43 qt
Engine Coolant Capacity11.1 qt
Engine Coolant Capacity8.9 qt
Engine Coolant Capacity8.2 qt
Engine Coolant Capacity8.8 qt

Engine torques

Exhaust Manifold to Cylinder Head BoltsUniformly tighten fasteners. ft-lbs
Intake Manifold to Engine Bolts14.7
Exhaust Manifold to Cylinder Head Bolts1st step:
Intake Manifold to Engine Bolts13
Exhaust Manifold to Cylinder Head Bolts1st step:
Engine Oil Pan Drain Plug22.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs
Engine Oil Pan Drain Plug18.0 ft-lbs

Chassis torques

Driveshaft Flange to Transmission52.0 ft-lbs
Steering Track (Rod End) Bolts111.0 ft-lbs
Front Wheel HubInstall a new nut and torque to 148.0 ft-lbs
Rear Wheel HubInstall a new nut and torque to 148.0 ft-lbs

Ignition

Cylinder Firing Order1-3-4-2
Cylinder Firing Order1-2-3-4
Spark Plug ManufacturerMotorcraft
Spark Plug Gap.028 in
Spark Plug Torque9 ft-lbs
Spark Plug ManufacturerMotorcraft
Spark Plug Gap.035 in
Spark Plug Torque11 ft-lbs

Battery & A/C

RefrigerantR134a
Refrigerant Capacity1.25-1.50 lbs
Oil GroupPAG
Oil Type46
Oil Capacity4.90 oz
RefrigerantR134a
Refrigerant Capacity1.38 lbs
Oil Capacity4.40 oz

Service checks

Pressure Test18-20 psi
Thermostat Opening Temperature180-207 °F
Pressure Test14 psi
Thermostat Opening Temperature176-183 °F
Pressure Test14 psi
Thermostat Opening Temperature194-223 °F
Residual Pressure46-80 engine running psi
Regulated Fuel System Pressure (With Vacuum)46-80 engine running psi

Brakes

Brake Caliper Bolt to Carrier TorqueFront: 22; Rear: 21
Brake Caliper Carrier to Hub Bolt TorqueFront: 111; Rear: 66 /; Front: 111; Rear: 86
ABS Sensor Torque7.0
Minimum Pad ThicknessFront: 0.059; Rear: 0.059 in
Vented Rotor Minimum Thickness for ReplacementFront: 1.034; Rear: 0.374
Maximum Rotor Runout0.002

Multi-step torque procedures OEM · verified

Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

13.7 ft. lbs.3.7 ft. lbs
211.0 ft. lbs.11 ft. lbs
326.0 ft. lbs.26 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Cylinder Head — tightening sequence 5 stages

Prep Do not reuse old bolts. Use new bolts coated with clean engine oil. Tighten all bolts to finger tight then continue on with the following procedure.

15.17 ft. lbs.5.17 ft. lbs
211.0 ft. lbs.11 ft. lbs
333.0 ft. lbs.33 ft. lbs
490 degrees90 degrees
590 degrees90 degrees
Intake Manifold to Engine Bolts — tightening sequence 1 stages

Prep 1st step: bolts 1, 2, 7: 1.4 ft/lbs · 2nd step: bolts 3, 4, 5, 6: 1.4 ft/lbs · 3rd step: bolts 1, 2: 13 ft/lbs · 4th step: bolts 3, 4, 5, 6: 7.4 ft/lbs · 5th step: bolts 1, 2: 13.2 ft/lbs · 6th step: bolts 7: 13.2 ft/lbs

7tighten bolts 3, 4, 5, 6 to 7.4 ft/lbs. See diagram IQ

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the engine oil and filter every 10,000 mi; spark plugs every 100,000 mi; coolant every 50,000 mi. The big-interval services (every 50,000 mi for coolant, and the transmission fluid) are the ones owners most often skip — on a lower-mileage example, assume the original fluids are still in it and check them first.

Every 10,000 miDrive Axle Assembly (inspect) · Driveshaft (inspect) · Driveshaft U-Joint (inspect) · Engine Oil Pan (inspect) · Tire & Wheel Assembly (rotate)
Every 20,000 miAccessory Drive Belt (inspect) · Brake Line (inspect) · Brake Linings (inspect) · Brake Rotor (inspect) · CV Joint Boot (inspect) · Cabin Air Filter (replace)
Every 30,000 miEngine Air Filter Element (replace)
Every 50,000 miEngine Coolant System (drain, flush & refill) · Hybrid Inverter (drain, flush & refill coolant)
At 100,000 miAccessory Drive Belt (inspect) · Engine Coolant System (drain, flush & refill) · Hybrid Inverter (drain, flush & refill coolant)
Every 100,000 miSpark Plugs (replace)
At 150,000 miDrive Belt (replace) · Transmission Assembly (drain & refill)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

The 2016 Ford Fusion Energi sits in a notable transition within its generation, reflecting a mid-cycle spike in complaints (1,455) after a steady decline from 2013 to 2015, yet still below the 2013 peak. Recalls dropped to 11—lower than the 13–19 range of prior years—while investigations and TSBs remained stable, suggesting Ford was addressing issues without uncovering new systemic flaws. Compared to 2017, which saw complaints fall sharply (1,030) alongside a steep decline in recalls (4), the 2016 model appears to be a relative outlier, though not egregiously so. Engine (298) and powertrain (225) complaints dominate, consistent with the generation’s broader trends, while crash (45) and fire (6) reports remain low. The data implies 2016 owners faced more reliability noise than later years, but no red flags emerge beyond typical mid-cycle refinement challenges. **Takeaway:** While not the quietest year, the 2016 Fusion Energi is a reasonable buy if priced competitively, as its issues align with expected wear areas rather than design defects unique to the model year.

11
Open recalls
NHTSA campaigns
167
Service bulletins
Manufacturer communications
5
ODI investigations
Office of Defects Investigation
1,455
Owner complaints
45 involved a crash · 6 a fire
NHTSA crash-test rating federal NCAP · out of 5 stars
Overall★★★★★
Frontal★★★★★
Side★★★★★
Rollover★★★★
Owner complaints by model year NHTSA · this generation & adjacent

Owner complaints filed with NHTSA, by component

All 1,455 complaints on record, top 8 components.

Engine298
Power Train225
Steering110
Unknown Or Other88
Engine & Engine Cooling77
Service Brakes43
Electrical System41
Wheels39

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

No recall campaigns on record with NHTSA for this vehicle as of the last data refresh.

Technical service bulletins NHTSA · verified

Showing 5 of 167 bulletins on record with NHTSA.

BulletinDateComponentSummary
20R01 S12024-08-08Unknown Or OtherCertain 2014-2015 Model Year Fiesta, 2014-2016 Model Year Fusion, MKZ and 2014-2016 Model…
SSM 524762024-04-24EquipmentAll accessory stick-on keyless entry keypads come with a wallet card containing the…
SSM 523352024-03-06Engine And Engine CoolingFor 2015-2024 Ford and Lincoln vehicles equipped with turbocharged engines and customer…
21B09 S22023-04-12Electrical SystemCertain 2014-2020 Model Year Multiple Vehicle Lines 3G Telematics Control Unit to 4G…
SSM 515362023-04-04StructureFor 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420
Catalyst system efficiency below threshold — Bank 1
P0300
Random / multiple cylinder misfire detected
P0171
System too lean — Bank 1
P0455
Evaporative emission system leak detected — large leak
P0128
Coolant thermostat below regulating temperature
P0442
Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN
Decode a VIN to confirm the transmission and build data for a specific Fusion Energi. OEM
Build data
Plant, GVWR class, engine and body data for any 17-character VIN.
Recalls
Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Reference guides

Cross-vehicle references for the kinds of data on this page.

Frequently asked

How much oil does the 2016 Fusion Energi take?

4.3 qt of 5W-20 meeting Ford specification WSS-M2C946-A or equivalent., per the factory manual.

Does the 2016 Fusion Energi have open recalls?

NHTSA lists 11 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the Fusion Energi get?

EPA figures are 22 city / 31 highway / 25 combined mpg.