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Incorrect ratio of air and fuel is often the main reason for the knocking sound heard in a Ford Fusion engine. When the combustion chamber doesn't receive the right balance of fuel and air, the fuel burns unevenly. Failure to address this issue can lead to damage to the piston and cylinder wall. Using a fuel with an incorrect octane rating can also cause knocking, as low-rated fuel may ignite prematurely. An air-to-fuel mixture that is too lean can be caused by a malfunctioning oxygen sensor, fuel pump, mass airflow sensor, or fuel injector. Insufficient fuel in the mixture results in delayed combustion, requiring multiple detonations for the mixture to burn at the correct speed.
I just replaced my alternator because it seemed like it had some issues, but then I put in a salvaged motor and it started knocking right away. I ended up swapping out the motor twice, but it still had the knocking sound. When I took off the belt, the knocking stopped, and I saw metal shavings coming out of the front of the alternator. I replaced the alternator, and the knocking finally stopped.
The banging noise usually happens when the combination of air and fuel is not right.