These engines use a wet timing belt that runs inside the oil pan and drives the oil pump. Over time, the belt can shed rubber particles, contaminating the oil and risking oil starvation. Belt failure can cause immediate catastrophic engine damage.
Most EcoBoost engines are direct injection only, meaning oil vapors coat the intake valves with no fuel wash to clean them. This leads to heavy carbon deposits, misfires, power loss, and poor fuel economy over time. Walnut blasting or chemical cleaning becomes necessary on high-mileage engines.
Chains can stretch prematurely, causing rattling at startup and incorrect timing. This may trigger timing-related codes or lead to engine failure if ignored. Often linked to poor maintenance intervals or oil viscosity breakdown.
Known internal block or head casting flaws allow coolant to enter one or more cylinders. Symptoms include misfires, white smoke, rough idle, coolant loss, and engine failure. Ford has issued TSBs and extended warranties for some affected models.
Early 1.6L engines had coolant circulation problems and weak block castings. Overheating can cause the block to crack, leading to sudden coolant loss and engine fires. This was the subject of a major recall.
Turbo bearings can fail due to heat, poor lubrication, or contaminated oil. Wastegates on smaller EcoBoost engines are known to stick or fail. Failure often presents as loss of boost, whining noises, or smoke from burning oil.
Faulty PCV diaphragms and separators can cause high oil consumption or oil pulled directly into the intake. This can worsen carbon buildup and trigger detonation under boost. Some engines ingest so much oil they cause misfires or runaway RPM.
Moisture collects in the air-to-air intercooler under certain humidity conditions. Water droplets are then sucked into the intake, causing misfires, stumbling, or stalling. Ford’s fix involved revised intercoolers with baffles and drains.
Some HPFPs develop internal wear leading to reduced fuel pressure under boost. Symptoms include hesitation, long crank times, and limp-mode activation. 10. Plastic Oil Pans Warping (1.5L, 1.6L, 2.0L) Ford switched to plastic oil pans to save weight. These pans commonly warp, leading to slow leaks and low oil levels. Revised designs have improved durability but issues still occur.
Under heavy load or tuning, rods can bend or break more easily than expected. Even stock vehicles have occasionally experienced rod failure when severely overheated.
Malfunctions in the IMRC system can cause rough running, power loss, or P2004/P2008 codes. Carbon buildup and worn actuators are common causes.