NHTSA's Office of Defects Investigation stated that they've received 98 consumer complaints regarding malfunctions of the canister purge valve in 2012 to 2018 Focus models. These cars were either previously recalled and repaired or weren't recalled but exhibited the same issue.
In October 2018, Ford recalled over 1.2 million vehicles of the 2012 to 2018 Focus models equipped with a 2.0-liter direct-injection gasoline engine produced before April 13, 2017, or a 2.0-liter turbocharged direct-injection gasoline engine produced before February 2, 2018.
The recall addressed the canister purge valve malfunction and powertrain control module software, as this software failed to detect the issue adequately. As stated in a document explaining the investigation by NHTSA, "A malfunctioning CPV can cause the engine to have a skewed air-fuel ratio, leading to a loss of power. It can also trigger the Malfunction Indicator Light (MIL) to illuminate, create unstable fuel gauge readings, and cause excessive vacuum in the fuel vapor management system, which may deform the fuel tank." To resolve this, dealers reprogrammed the powertrain control module and replaced the canister purge valve as needed.
Subsequently, in July 2019, Ford launched another recall involving approximately 57,000 vehicles from 2012 to 2014 and 2017 Focus models. These vehicles were also part of the 2018 recall but didn't have their powertrain control module updated as planned.
NHTSA noted that they have initiated an investigation to assess the scope and remedy of Ford's 2018 recall. Ford spokesperson Maria Buczkowski stated that the company is "working with NHTSA and providing support for its investigation."
NHTSA also mentioned in August this year that they're probing into Ford's handling after the recall of nearly 50,000 Mustang Mach-Es in June 2022, as they received new power loss reports.
According to NHTSA's data, up to now this year, Ford has initiated 44 recalls, the most among all carmakers, affecting over 4.6 million vehicles.
