Sailorman Posted May 12, 2012 Share Posted May 12, 2012 2010 Fusion HEV with 40k KMs. Service Engine light came on about a week ago and stayed on for a few days then turned off and came back on again. Dealership reprogrammed the PCM per TSB MT 091913A. After a couple of days the Service Engine light is back on; so back to the dealer on Monday. Anyone else having a similar problem. 0 Quote Link to comment Share on other sites More sharing options...
jeff_h Posted May 12, 2012 Share Posted May 12, 2012 The CEL can come on for many reasons, mine came on once at 63k miles and stayed on (so no intermittent display like your situation), and while my car was running fine, I took it to dealer and the oxygen sensor was out of limits (their term) and needed to be replaced. I don't know where you are located, but if you have an autozone near you, I think you can go there and get a free reading to find out the error code... and then they can look it up or you can find the error codes on line (link is on other threads around here) -- or you can wait to see the friendly dealer again. Good luck! 0 Quote Link to comment Share on other sites More sharing options...
dennisw Posted May 13, 2012 Share Posted May 13, 2012 Without a computer code it's impossible to say what may be causing this. Did the dealer find a pending or active code? This sounds like a very minor problem, maybe a bad seal on the gas filler door or bad fuel. There are just far to many issues that this could be. But normally when the light comes and goes it is related to fuel system usually a bad tank of gas. Did you have a new tank of fuel within a day or so when this started? 0 Quote Link to comment Share on other sites More sharing options...
Milan_OH Posted May 13, 2012 Share Posted May 13, 2012 Sailor - I've seen this twice with my '10 MMH. Once right after the 30K warranty expired, and just last week @ 48K. Both times it was on for a couple days then off with no noticeable change in performance....mpg climbing with each tank as avg daily temps rise. Next time I'll at least get the code. I haven't had either firmware update performed, I doubt it related to that. 0 Quote Link to comment Share on other sites More sharing options...
Sailorman Posted May 13, 2012 Author Share Posted May 13, 2012 Work order says: "39982 RECALEM 04 091913A 30 EEC TESTS PO400, REPROGRAM PCM AS PER TSB PER MT MT 091913A" Assume this is refering to TSB 09-19-13. I did get new fuel before the code appeared so that might be a factor but did purchase from a high volume reputable station that I use all the time. Might try refuelling with higher octane fuel and carefully remove the nozzle. 0 Quote Link to comment Share on other sites More sharing options...
dennisw Posted May 14, 2012 Share Posted May 14, 2012 That is a generic code for exhaust gas recirculation flow. This was most likely a leak at the filler cap, maybe the opening did not seal properly after you filled up. There are steps to clean the door in the owners manual. 0 Quote Link to comment Share on other sites More sharing options...
lolder Posted May 14, 2012 Share Posted May 14, 2012 It is unlikely that fuel is the problem. The CEL light is usually an emissions system alert, particularly if you notice no operational changes. Since there is no gas cap on the FFH that would not be the problem unless the cap-less system is having a problem. There have been no reports of that problem on this forum. Most parts of the emission system are covered by various warranty periods. You need to check your Warranty booklet to see if the repair will be covered. I recently had a CEL on a 2004 Toyota Avalon. Auto-Zone's free test indicated a fuel vapor leak. There was nothing obviously wrong with the old one but after re-securing the cap, the CEL remained on even after enough cycles to turn off the light. A $10 gas cap solved the problem. Keep us informed. 0 Quote Link to comment Share on other sites More sharing options...
FusionDiffusion Posted May 14, 2012 Share Posted May 14, 2012 (edited) Just to be clear P0400 = Exhaust Gas Recirculation Flow Malfunction. The EGR really has nothing to do with the EVAP system, so P0400 would not possibly be the result of loose gas cap. Loose gas cap code is P0455 (gross EVAP leak) FYI. Edited May 14, 2012 by FusionDiffusion 0 Quote Link to comment Share on other sites More sharing options...
dennisw Posted May 14, 2012 Share Posted May 14, 2012 Here go all the arguments on a simple problem. Yes a loose cap will cause this alert. The evap system is tied to the fuel system and sends fuel vapors back to the fuel system i.e. gas tank. A loose cap or in this case a filler door that is not sealed properly will not allow the system to pressurize and cause evaporative problems and this does trip this code. And it has been discussed on this forum before, there have been many fuel door problems reported. This shows the reason why the fuel codes do not always tell you exactly what the problems are they aim you in the right direction for trouble shooting. I will be very surprised if like I said from day one that this is not caused by a simple loose cap, more so than the first GUESS bad fuel, or loose fuel door. It is also automatic that the dealer installs all software updates when a problem is being trouble shot, just because they flashed the computer does not mean this was the problem, or that it would even correct this problem. Follow the fuel door cleaning instructions and this problem will more than likely go away, if it has not already. 0 Quote Link to comment Share on other sites More sharing options...
dennisw Posted May 14, 2012 Share Posted May 14, 2012 Before I'm blasted for last statements when I wrote loose cap, I am talking filler door on this particular application. I've been fixing these problems for so long it was just an automatic slip of proverbial tongue to refer to gas cap. And don't get me wrong this could be a dirty EGR valve also, but by how it is acting I still say filler door. At least you have a code to start your investigation. And you did just fill up before this happened, listen to me or not but this is where you or whoever starts the search. And I did refer to bad fuel before I had anything to go on, and I stated this at the time. But by the lack of info in the starting post fuel or emission I.e filler door was the most logical place to start. 0 Quote Link to comment Share on other sites More sharing options...
tr7driver Posted May 14, 2012 Share Posted May 14, 2012 I forgot to close the fuel door after a recent fill up and drove for a couple of days before I discovered it was open. It didn't throw any codes. 0 Quote Link to comment Share on other sites More sharing options...
dogo88 Posted May 14, 2012 Share Posted May 14, 2012 (edited) I forgot to close the fuel door after a recent fill up and drove for a couple of days before I discovered it was open. It didn't throw any codes. It shouldn't. The capless design is sealed inside the door. Dan Edited May 14, 2012 by dogo88 0 Quote Link to comment Share on other sites More sharing options...
Sailorman Posted May 15, 2012 Author Share Posted May 15, 2012 Had the car back into the dealer today, and they told me that they have to order a part. Said it's an EGR part; the work order says "40227 POO USA" ; not sure if that means anything. The faults were cleared, so the light is off for now. They said 3-5 days to get the part as its coming from the USA (I'm in Canada). It appears unrelated to the fuel cap problem some of you were suggesting. THe car is under warranty so I'll let the dealer figure it out. I presume if they thought the fuel cap system was the problem they would sort that. 0 Quote Link to comment Share on other sites More sharing options...
lolder Posted May 15, 2012 Share Posted May 15, 2012 Sticky EGR valves used to appear in higher mileage cars. Carbon and other substances used to cause malfunctions. Yours is a low mileage car. Let us know precisely what the part is if you can. The FFH ICE seldom goes to high RPMs unless you floor it and it spends most of it's life between 1200 and 2000 RPM. It uses a lot of EGR all the time along with high throttle plate openings. You probably have just a random problem. 0 Quote Link to comment Share on other sites More sharing options...
Sailorman Posted May 16, 2012 Author Share Posted May 16, 2012 Sticky EGR valves used to appear in higher mileage cars. Carbon and other substances used to cause malfunctions. Yours is a low mileage car. Let us know precisely what the part is if you can. The FFH ICE seldom goes to high RPMs unless you floor it and it spends most of it's life between 1200 and 2000 RPM. It uses a lot of EGR all the time along with high throttle plate openings. You probably have just a random problem. I confirmed with the dealer that the part no. they are replacing is #CX 2193 which is the EGR Valve. Car goes in Friday so we'll see if replacing this part resolves. The CEL is back on again. 0 Quote Link to comment Share on other sites More sharing options...
Sailorman Posted May 18, 2012 Author Share Posted May 18, 2012 I confirmed with the dealer that the part no. they are replacing is #CX 2193 which is the EGR Valve. Car goes in Friday so we'll see if replacing this part resolves. The CEL is back on again. New EGR valve was installed today. Dealer has no idea why the original valve would fail. Will report back if CEL comes back on. 0 Quote Link to comment Share on other sites More sharing options...
Sailorman Posted May 21, 2012 Author Share Posted May 21, 2012 New EGR valve was installed today. Dealer has no idea why the original valve would fail. Will report back if CEL comes back on. 3-days driving and light has so far stayed off, so faulty EGR Valve must have indeed been the cause. No idea why the EGR valve would fail on a 2 year old car with 40,000kms. EGR failure is more likely a high mileage failure after many years of operation. Wonder if this is sign of whats to come. Has anyone put a lot of miles on their HEV and had any problems. This is my first service issue. 0 Quote Link to comment Share on other sites More sharing options...
jeff_h Posted May 21, 2012 Share Posted May 21, 2012 Wonder if this is sign of whats to come. Has anyone put a lot of miles on their HEV and had any problems. This is my first service issue. I now have 120k miles on my 2010 FFH, noted in an earlier post that the oxygen sensor needed replacement at 63k miles (though it was running fine) and I recently got another set of tires and during the alignment check they said the right-front wheel bearing needed replacement, which they then replaced. So with driving over 40k miles per year (don't hit the 3 year mark for another couple months), I am very satisfied with how the car has performed. 0 Quote Link to comment Share on other sites More sharing options...
strangedaddy Posted October 24, 2014 Share Posted October 24, 2014 I just hit 110K on mine and I am starting to wonder if my wheel bearings are going bad too. Just started to hear a hum. 0 Quote Link to comment Share on other sites More sharing options...
hstevenson Posted January 3, 2016 Share Posted January 3, 2016 I have a 2010 Ford Fusion SE. Early last year I got the "check fuel fill inlet" error message. I checked the manual and got gas a few more times and it went off. Later, same message only now the "check engine light" comes on. No matter what I do, I can't get it to go off. My mechanic (and the internet) says it's the EVAP sensor and the neck of the fuel system needs to be replaced. My mechanic says he replaced one earlier (the part alone was $300) and the thing malfunctioned again a few months later. Now, I can't get my car inspected because the CEL won't go off. I have 168K miles and, this aside, no problems. Love this car but frustrated. Does anyone know if there was a recall on this part? Any cheap fixes? 0 Quote Link to comment Share on other sites More sharing options...
lolder Posted January 3, 2016 Share Posted January 3, 2016 (edited) It sounds like the cap-less filler may have a problem. I'm not sure if that could be cleaned. Maybe spraying some WD 40 liberally around the filler opening where the little bumps are and inserting and removing the supplied funnel a few times. Evaporative emissions problems are always tricky with aging cars. Try to verify the problem. Advance Auto Parts reads the codes for free. Edited January 3, 2016 by lolder 0 Quote Link to comment Share on other sites More sharing options...
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