NHTSA Preliminary Evaluation PE18007

On July 16, 2018, the Office of Defects Investigation (ODI) opened this Preliminary Evaluation (PE) to investigate alleged instances of sudden stalling without warning on model year (MY) 2013 Ford Escape vehicles equipped with 1.6L GTDI turbocharged engines. Complaints alleged that vehicles stalled due to engine overheating, resulting in a delayed or no restart condition. When the investigation was opened, ODI had received 40 Vehicle Owner Questionnaires (VOQs). At this time, ODI has received 173 VOQs with five reported fires and no reported crashes. In investigating the incidents alleged in the VOQs, ODI revisited an apparently related recall that Ford had issued in November 2013 (Recall 13V-583). In Recall 13V-583, Ford recalled all MY 2013 Ford Escape vehicles equipped with the 1.6L engines, built from October 5, 2011, to June 2, 2013. This recall addressed potential engine compartment fires due to localized overheating of the engine cylinder head leading to cracks that can cause oil leaks onto a hot engine surface. The remedy was to provide several enhancements to the engine shielding, cooling and control systems, which involved recalibration of the powertrain calibration module and the instrument cluster system. The recalibration implemented a “Failure Mode Effects Management” (FMEM) strategy to alert the driver of a low coolant state and limit the power to the engine to prevent overheating to the point of cracking the cylinder head. The FMEM strategy includes a “Low Engine Coolant – Service Required” message in the instrument cluster when the coolant reaches a prescribed low level and the engine continues to perform normally, and a coolant level sensor that was incorporated such that if the coolant level is further reduced, the engine enters a reduced power mode (vehicle speed limited to about 40 mph). If the vehicle is driven farther and coolant is not added to the vehicle, the vehicle enters a further reduced power mode and audible and visual alerts will appea