Other Fuel System Fuel Injection System problems of the 2015 Ford Fusion

This is a reoccurring issue with the direct fuel injection system (gdi). The high pressure pump is ground into the top of the camshaft cam and causing fuel rail failure, engine codes p0087 & p219a. The dealership has repaired this once under warranty. Ford refuses to repair again, since my warranty expired while we were in state lockdown order. This gdi direct fuel injection vs. Multi-port injection was rushed to market to meet the new fuel economy mandates set by congress and it has failed on this vehicle 3 times now, causing seriously dangerous driving conditions. Fmc wont repair again even though they know of this systemic issue. I am attaching a copy of the diagnostics from Ford with the extensive repair/parts list. I see on almost every Ford complaint website the issues with the early gdi fuel systems on their eco boost models. My car only has 54000 miles and this is the third time for needed repairs. Fmc case# cas27469187.

Started car, got dashboard light on 7. 6. 19 mileage 27721. Car running rough, about to stall,etc. Error code p0302. Cyl. #2 ignition coil replaced. Then, 2 weeks later got dashboard light again, same code p0302. Mechanic (private)replaced perceived faulty ignition coil as previous. On 9. 23 . 19 car started,. Car runs rough, almost stalls dashboard lights again. This time we take it to royal oak Ford service dept. They get p0302 and advise us to change spark plugs. $307. 29 charge. Upon inspection of spark plugs I note all plugs are heavily coated in carbon. I check the tailpipe and the inside is also heavily carbon coated. Shortly after I find information that most direct inject engines have this problem. It was not hard info to find. Because of direct injection the valves do not receive the benefit of detergent gasolines and become heavily coated in carbon. This is an oversimplified explanation of what is occurring. , but makes the point. I confirm findings with and show plugs to, my mechanic who confirms ;that these direct inject engines have an issue the manufacturers can't or haven't corrected, which results in the condition my spark plugs were found in. I found notsb's on the subject. Mechanic recommends a gdi service, which includes pulling all valves and cleaning them. He also recommends anyone with a di engine to do this at least once a year to keep vehicle running smoothly and to get maximum life out of the plugs. By the way, first service interval for plugs on this car is 100,000 miles. This is the experience I've been exposed to so far, but do know that it can get much worse (affecting other parts of the engine) fwiw the mechanic believes the manufacturers (in this case Ford) are well aware of these issues with direct inject designed engines. Pic of plugs incl. Below.

In October 2017 my Fusion stalled out four times (three various days and one day 15 minutes between stalls) and again on November 4th. Each time I was driving less than 10 mph; four times on a city street and once in a parking lot. In each case I had been driving for an hour or more and then stopped and turned off the car for a period of time (1/2 hour or so). When I got into the car to drive away the car would start normally and then within a few minutes after the car was put into drive and moving it would start to sputter and shake and then stall out. In each case no engine check light came on. I would wait a few seconds, press the start button, the engine would crank a few times, and then it would start. Each time this occurred I ran a vehicle health report and nothing was noted. The car was taken to a Ford dealer where they could not replicate the issue. In doing research, I believe there is an issue with the fuel injection throttle body.