ZeroPlus

This is total speculation on my part, but I suspect there are two separate issues here. The ignition remaining on sounds like a mechanical glitch in the ignition switch itself. The inability of the car to start after a fill up sounds like an evap system issue - there is an overload of gas vapors in the combustion chambers. Try not filling it to the top and see what happens. Over filling the gas tank can send raw gas to the charcoal canister and damage it.

Buy a Toyota or Lexus next time.

Any connection?

Working on a 2009, it has the same type of noise coming from that general area, but not as intense as yours. It quiets down after several minutes. I have not determined the source, so I will be interested in this thread.

On a 2009 Edge I worked on , the Ford dealer and the Ford Internet site said the vehicle used a Motocraft FL500 filter. The previous oil change had been done at a Ford dealership, and it had a Purolator PL20195 installed - which is equivalent to a FL400 Motocraft oil filter. I was totally confused, but put on another Purolator L20195 and it appeared to seal correctly. Splitting applications of non- interchangeable oil filters in a mid-month production run is absurd! The car sticker provides the month/year of production only - not the day of the month. The manual says FL400 and FL500 - I thought it might be both, but it is either/or. These oil filters thread pitches are different and they are not interchangeable. I will stick with the FL400 thread pitch filters, as it appears to work.

Thanks for noticing that error on my part - it is a 2009 model.

A 2009 Edge with the 3.5L engine had a production shift mid -January of the 2019 production run. Prior to 1-16-09, it called for a FL400 oil filter. After that date, it shifted to a FL500 (Motocraft). The thread pitches on these 2 filters are different - FL400 is standard and the FL500 is metric - they should not be interchangeable. The dealer said the model I had was the FL500 group, but then put on a Purolator TL20195 oil filter, which is the equivalent of the Motocraft FL400. The insert in the manual says FL400 - SB12 or FL500, which is confusing, given the different thread pitches on the filter base. I would have thought the threads on the oil filter mounting plate would be damaged with the wrong filter - how can 2 different thread pitches be applicable?

Very interesting photo! Obviously this varnish would also be found on other engine components. The choice is obvious - synthetic. Maybe that is why conventional oils always had a suggested change interval of 3000 miles.

The Ford dealer had put in a Purolator TL 20195 in a 2009 Edge with a 3.5L engine. The thread pitch on this filter is UNF-28. The FL 500 Motocraft filter has a thread M22X1.5 -6H. But they are supposedly interchangable on this model, according to the manual. The Purolator L22500 has the metric thread pitch, so that should fit too. I don't understand how both thread pitches can be interchangable. I put in a Purolator L20195 and it seemed to fit. Update - these 2 filters are NOT interchangeable. You must determine the correct one by the exact day of the month the car was made. I think the manual insert inferred to either/or - but not both. The vehicle used the FL400 thread pitch version. The FL500 would not have worked.

Alignment?

Could the salvaged part be defective?

Ford's attitude and response is unacceptable. It implies Ford has outsourced parts production, probably to China. Does the part have to be new and/or a genuine Ford part? Depending on what it is, you might get by with a genuine Ford part from a salvage yard. That might cover the stipulations of the warranty and keep it in force. EBay is the vendor for a lot of salvage yards - it might be worth checking it out. Your mechanic could verify if the part sufficiently provides a temporary but reliable solution to getting the vehicle operational. Be sure to bounce the idea off Ford, so they don't try to pull a fast one on you. Next car - buy a Toyota or Honda.

You need a better mechanic. The dealer's mechanics are now just guessing and throwing parts at it. Find an electrical specialist.

Take a matching nut off the cover and then compare its dimensions at the hardware store. It is probably metric. I doubt Ford would have some piece of common hardware like a nut be so exclusive as to be only available from their parts department.

What is the KAM?

The advice about a bad wire between the coil and PCM came to mind also. A fault that the PCM can't identify often confuses mechanics. Accurate trouble shooting often requires thinking outside of the proverbial box. I will be interested in hearing your eventual resolution, as i have a similar situation in a Toyota Sequoia.

Straight anti-freeze does not disperse heat as well as a 50/50 mix.

Stick with the recommended filter. Not worth the minimal capacity addition for the risk of leaks/pressure differentials.

I just discovered that someone put on the equivalent of the FL400S oil filter on a 2009 Edge SEL. This model calls for a FL500S oil filter and the 2 different filters are not compatible. The FL400S has about a 2mm smaller hole, so it was forced onto the adaptor stem. My question - is the oil filter adaptor stem on the car likely damaged, as the filter dimensions are different (400 is english increments and 500 is metric). I don't want to pull the present filter off, only to discover the mounting stem has stripped threads and then nothing fits. Ford made a serious blunder switching filter applications with the same model year - even most car parts places couldn't distinguish the correct application. The 400S and 500S filters have different sized holes and the thread pitch is different.