Ford Bronco & Escape Fuel Injector Recall: Critical Safety Information All Owners Must Know

Ford has issued a critical safety recall (Recall 23S56/NHTSA 23V-618) impacting certain 2020-2023 Ford Bronco Sport and 2022-2023 Ford Escape vehicles equipped with 1.5L engines due to a potentially defective fuel injector that can leak fuel and create an unacceptable fire risk. Owners of affected vehicles should immediately check their VIN with Ford or the NHTSA website and contact a Ford dealership for inspection and necessary free repairs without delay.

This recall addresses a serious defect where a crack can develop in the plastic housing of a specific fuel injector. If this crack forms, gasoline can seep out under high pressure within the engine compartment. Fuel leaking onto hot engine surfaces, such as the exhaust manifold or turbocharger, presents a clear and significant danger of igniting an engine compartment fire. Such a fire can rapidly engulf the vehicle, posing severe risks of personal injury, death, and extensive property damage. Safety must be the absolute priority.

Which Vehicles Are Specifically Affected?

The recall targets specific model years and build dates. Not all Bronco Sports or Escapes are involved.

  • Ford Bronco Sport: Certain vehicles manufactured between February 22, 2020, and March 23, 2023.
  • Ford Escape: Certain vehicles manufactured between June 2, 2021, and March 23, 2023.

Crucially, this recall ONLY applies to models equipped with the 1.5L EcoBoost (GTDI) gasoline engine. Vehicles with the 2.0L EcoBoost or hybrid/powerboost powertrains are NOT included in this specific recall. Ford estimates approximately 220,000 vehicles in the United States are affected, with many more potentially impacted in Canada and other global markets. Final vehicle inclusion is always determined by the Vehicle Identification Number (VIN).

Understanding the Failure Mechanism and Fire Risk

The defect centers on a critical component: the fuel injector responsible for delivering precise amounts of gasoline into the engine's combustion chamber at extremely high pressures. The specific injector models involved in this recall have demonstrated a susceptibility to developing hairline cracks in their plastic body over time under the stress of normal engine operation.

  • The Crack: This crack typically initiates and propagates within the plastic housing near a crucial seal.
  • The Leak: Once a crack exists, pressurized fuel (typically between 100 psi to over 2000 psi, depending on operating conditions) can escape through it directly into the engine compartment.
  • The Ignition Point: Modern engine compartments are densely packed with very hot components necessary for operation. Key among these is the exhaust manifold (which directs extremely hot exhaust gases out of the engine) and the turbocharger (which operates at exceptionally high temperatures). Fuel leaking directly onto or near these red-hot components provides the necessary heat source for ignition.
  • The Consequence: A fire igniting within the engine compartment can spread rapidly. Consequences range from complete vehicle loss to catastrophic outcomes including severe burns or fatalities for occupants or bystanders. Even a minor leak significantly increases risk.

Symptoms Drivers Might Notice (Do Not Ignore Warning Signs!)

While the failure can sometimes occur without prior noticeable symptoms, drivers should be acutely aware of potential warning signs. If you experience ANY of these, safely stop driving the vehicle, turn the engine OFF immediately, exit the vehicle, and contact Ford Roadside Assistance or your dealership. Do not restart the engine. Symptoms include:

  • Strong Smell of Gasoline: An unusually potent or persistent odor of raw gasoline inside or outside the vehicle, especially noticeable near the hood, after driving, or when the engine is hot, is a major red flag.
  • Visible Fuel Leak or Pooling: Check the ground underneath the engine compartment area when parked. Any visible drips, trickles, or pools of liquid gasoline are an absolute emergency indicator.
  • Engine Misfires or Hesitation: While misfires can have many causes, a significant fuel leak from an injector can disrupt the precise air/fuel mixture needed for smooth operation, leading to rough idling, stumbling, hesitation during acceleration, or obvious engine vibration.
  • Unusual Engine Sounds: A hissing or spraying sound originating from the engine compartment could potentially indicate pressurized fuel escaping.
  • Illuminated Malfunction Indicator Lamp (Check Engine Light): The vehicle's engine control system may detect a problem related to the fuel delivery system or engine misfire and trigger the check engine light. While not specific to this issue, it warrants immediate diagnosis, especially combined with other symptoms.
  • Smoke or Visible Fire: Obvious smoke emerging from under the hood or visible flames constitutes a critical emergency. Safely evacuate the vehicle and call emergency services immediately.

Ford's Official Recall Repair Procedure

Ford has directed its dealerships to perform a specific repair sequence on all affected vehicles identified by VIN. This repair is performed entirely free of charge to the vehicle owner.

  1. Inspection: Dealership technicians will carefully remove the engine appearance cover (if equipped) and visually inspect the top of each fuel injector on the 1.5L engine.
  2. Injector Identification: They will determine if any of the injectors present are part of the suspect population identified as potentially defective. This involves checking specific part numbers and markings.
  3. Injector Replacement: If any injector from the suspect population is found installed on the vehicle, the dealer will replace ALL four (4) fuel injectors with new, redesigned injectors that do not contain the defective plastic component causing the cracking issue. This complete replacement is crucial, even if only one injector is identified as suspect, to ensure long-term reliability and eliminate the fire risk.
  4. ECU Reprogramming: In conjunction with injector replacement (whether performed now or later), the dealership will also perform a specific software update (known as a Powertrain Control Module / Engine Control Unit reflash). This update enhances the vehicle's ability to detect potential injector leaks. If the system detects a significant drop in fuel rail pressure that might indicate a leak, it will activate an "Engine Malfunction Indicator Light" and significantly reduce engine power to "limp-home mode." Crucially, it will also deactivate the high-pressure fuel pump immediately upon engine shutdown. This dramatically reduces residual fuel pressure in the system after the engine is turned off, lowering the risk of fuel spraying if a crack were present and mitigating post-shutdown fire potential. This software change is a key safety enhancement.
  5. Precautionary Replacement (If No Suspect Injectors Found): If an affected vehicle is inspected and none of the currently installed fuel injectors are from the suspect population, technicians will only perform the critical PCM/ECU software update at this time. The injectors themselves will not be replaced unless they later exhibit problems. Owners should still be vigilant for symptoms.

Immediate Action Steps for Bronco Sport and Escape Owners

  1. Confirm Your Vehicle is Affected: DO NOT ASSUME. Your first step is verification. Use your 17-digit Vehicle Identification Number (VIN):
    • Ford Recall Website: Visit the official Ford Recall Information page: https://www.ford.com/support/recalls (or your regional Ford website) and enter your VIN.
    • NHTSA Recall Website: Visit the National Highway Traffic Safety Administration (NHTSA) recalls page: https://www.nhtsa.gov/recalls and enter your VIN. This is the authoritative US government source.
    • Check Mail: Ford is required by law to mail recall notifications to registered owners. If you received a letter, your vehicle is affected. Do not ignore it.
  2. Schedule Repair IMMEDIATELY if Affected: Contact your local Ford or Lincoln dealership's service department to schedule an appointment. Clearly state you are calling about Recall 23S56 / NHTSA 23V-618. Demand priority scheduling due to the fire risk. Inquire if loaner vehicles are available during the repair, as injector replacement can sometimes take several hours or require the vehicle for a full day depending on dealership workload and parts availability.
  3. Heed Warning Signs: REVIEW SYMPTOMS. If you experience any gasoline smell, notice a leak, see the check engine light illuminate (especially with drivability issues), or observe smoke or fire, STOP DRIVING. Park in a safe, open location away from structures or other vehicles, turn off the engine, and evacuate the vehicle. Call Ford Roadside Assistance (if applicable and safe) or have the vehicle towed directly to a dealership. Do NOT restart the engine.
  4. Verify Repair Completion: After the dealership performs the work, ensure you receive documentation detailing the repairs completed. The repair order should specifically list:
    • Completion of Recall 23S56 (or your regional equivalent code).
    • Replacement of all four fuel injectors with updated part numbers (if they were replaced).
    • Confirmation of PCM/ECU software reprogramming to the latest calibration level.
    • Keep this paperwork for your vehicle's maintenance records and proof of recall completion.

Long-Term Maintenance and Vigilance

Even after recall repairs are completed, responsible vehicle ownership includes continued awareness:

  • Maintain Awareness: Be cognizant of any unusual gasoline odors post-repair. While the new injectors are designed to eliminate the defect, any fuel smell warrants investigation.
  • Routine Inspections: During regular oil changes or maintenance visits, request that technicians visually check the top of the engine for any signs of fuel residue or leaks around the injector area. This provides an extra layer of safety monitoring.
  • Software Updates: Ensure your vehicle receives all future software updates as recommended or required by Ford. These updates often contain important performance, efficiency, and safety improvements that build upon existing systems like the enhanced leak detection strategy.

Why the Recall Involves Multiple Models (Bronco Sport & Escape)

The Ford Bronco Sport and the current generation Ford Escape share the Ford C2 platform. This platform sharing is a common automotive industry strategy that allows manufacturers to leverage significant engineering, parts, and production efficiencies across different models. Crucially, this platform sharing means both the Bronco Sport and Escape utilize identical powertrain components within the same engine compartment architecture. The 1.5L EcoBoost engine is offered in both model lines, and the fuel injectors involved in this defect are the same component used in both vehicles during the specified build periods. Therefore, the underlying defect and its associated fire risk apply equally to affected Bronco Sport and Escape models with the 1.5L engine built within the recall date ranges.

Frequently Asked Questions (FAQs)

  • Q: How urgent is this recall? A: Extremely Urgent. A risk of under-hood fire leading to catastrophic outcomes is among the most severe safety issues. Schedule repair immediately.
  • Q: I haven't noticed any problems. Do I still need the recall? A: ABSOLUTELY YES. The defect involves an injector crack that can develop spontaneously during normal driving without initial symptoms. The fire risk remains present until repaired.
  • Q: What if I only get the software update and not the injectors replaced? Is my vehicle safe? A: It depends. If your dealer confirms none of your current injectors are the suspect type during the initial inspection, the immediate risk is mitigated by the software update alone. However, only injector replacement permanently eliminates the underlying defect possibility. If any suspect injector is present (and replaced), you get both repairs. Always follow Ford's determination based on inspection.
  • Q: How long will the repair take? A: Injector replacement typically takes several hours (~4-8+ hours labor) plus software update time. Expect the vehicle to be at the dealership for most of the day. Contact your specific dealership for their schedule and availability of parts/loaners.
  • Q: Can I drive my car if the recall is incomplete and I have no symptoms? A: Ford advises owners of affected vehicles to schedule the repair as soon as possible. While the risk may be statistically low at any given moment for a vehicle without symptoms, the potential consequence is severe. Driving increases the stress on components. It is a risk versus necessity judgment. If you must drive, be hyper-vigilant for symptoms and park outdoors away from structures until repaired. Ford does NOT explicitly say "do not drive" unless symptoms are present.
  • Q: What if my car is part of the recall but I had injectors replaced already (for unrelated reasons)? A: Your dealer will inspect the injectors. If the injectors currently installed are the updated version (not the suspect part), only the software update will be performed.
  • Q: How much does the repair cost? A: The recall repair (inspection, software update, and injector replacement if needed) is performed FREE OF CHARGE at Ford dealerships. Do not pay for this specific recall work.

Conclusion

The Ford Bronco Sport and Escape fuel injector recall (Recall 23S56 / NHTSA 23V-618) is a critical safety campaign addressing a genuine risk of under-hood fire in affected 2020-2023 Bronco Sport and 2022-2023 Escape vehicles equipped with the 1.5L engine. The defect lies in the potential for a specific fuel injector to crack, leading to pressurized fuel leaks onto hot engine components. Owners have a responsibility to immediately verify if their vehicle is impacted using their VIN via Ford or NHTSA websites. If affected, scheduling an appointment at a Ford dealership for the free recall repair is paramount. This repair involves an essential safety software update to enhance leak detection and pressure reduction, and potentially the replacement of all four fuel injectors with redesigned parts. Ignoring this recall or delaying repairs knowingly exposes yourself, your passengers, and others to an unacceptable risk. Heed any signs of fuel leaks or odors as emergencies requiring immediate cessation of driving. Prompt action ensures the safety and reliability of your Ford Bronco Sport or Escape.

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