Ford 3.5 EcoBoost Engine Problems
Ford Ecoboost 3.5 by Numobeer - CC-BY-SA-4.0
Ford’s EcoBoost line of engines has become synonymous with the effective combination of power and fuel efficiency. The 3.5L V-6 variant lives at the lineup’s center and offers prodigious power to everything from the Fusion sedans to F-150 trucks. In general, the 3.5L Ecoboost continues to grow its fan base due to its strength and durability. Still, some issues remain common on a few variants of this engine.
This article will dig into the common Ford 3.5 EcoBoost engine problems and detail the issues and how much it will cost to repair them.
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The Most Common Ford 3.5L EcoBoost Problems:
- Intercooler Condensation. Cost to fix: $500
- Timing Chain Wear. Cost to fix: $2000
- Ignition Issues. Cost to fix: $241-$284.
- Carbon Buildup. Cost to fix: $400-600
Intercooler Condensation
Problem:
In high humidity conditions, some models of F-150 have issues with water being trapped (vs. vaporized) in the intercooler. This is due to a design flaw that does not allow water to be quickly evaporated in high humidity conditions. This can cause stumbling or hesitation under high boost loads or highway speeds. Ford redesigned this part in later years to avoid the issue.
Cost:
The aftermarket offers a solution for this problem via an apparatus called a “catch can.” Essentially, these devices use the vacuum created by the turbos to catch oily water vapor from the intercooler. These rigs run from $200 to $400 and can easily be installed by a mechanic for around $150.
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Timing Chain Wear
Problem:
Since the Ecoboost is a turbocharged engine, it is even more imperative to maintain due to the stress that the oil is consistently under. If maintenance is not kept up, the timing chain can wear out prematurely, along with the chain tensioner and pulleys. Once this happens, the engine will fall out of timing alignment and experience many issues.
Cost:
Unfortunately, this is an expensive repair as it requires a good bit of engine teardown to accomplish the task of replacing the timing chain parts and pieces—figure north of $2,000 for this intensive job.
Ignition System Issues
Problem:
The 3.5L Ecoboost was apparently prone to ignition issues that come from the spark plug. It’s such a prevalent and disruptive issue that drivers will quickly notice. The engine assemblage comes with a direct fuel injection system that works with a twin-turbo system. Although the turbo system can provide sufficient power to the combustion system, it can potentially overload the ignition system.
As time goes on, wear and tear will affect the spark plugs and ignition coils. While this is a reasonably simple fix by replacing the spark plugs, this issue will cause more severe problems to your Ecoboost engine. Some of the most common symptoms of this issue are:
- Shuttering
- Engine misfires
- Illuminating check engine light
Cost:
Thankfully, the ignition system issue of the 3.5L Ecoboost doesn’t require significant repair. As mentioned, the primary fix is to replace the worn-out parts. In this case, it’s the Ecoboost engine’s spark plugs. The spark plug part is about $75, and you can go the DIY route for the installation. However, if you go to a mechanic, expect to pay between $241 and $284.
Carbon Buildup
Problem:
Carbon build is primarily a concern on 1st-gen EcoBoost engines. The first-generation EcoBoost engines only use direct injection, meaning the fuel is sprayed straight into the cylinders. As a result, carbon can accumulate inside the valve intakes. While it’s normal for engines to experience oil blow-by, it’s particularly bad in 1st-gen EcoBoosts since nothing helps clean the ports and valves.
This results in carbon buildup that restricts airflow into the cylinders. While this issue doesn’t strictly require immediate attention, it may lead to drivability issues like power loss, misfires, and rough idling.
Again, this was mainly a concern with first-generation EcoBoost engines. Ford corrected this design flaw with the second-gen 3.5 EcoBoost.
Cost:
The best approach is not to allow the carbon to accumulate so bad that it causes problems. However, once the buildup becomes excessive, an effective fix is to conduct walnut blasting. This solution requires a good-quality shop vac and walnut media shells. Including labor, you may have to pay $400-600+ for this fix. Unless you know what you’re doing, it’s better to let the professionals handle this job.
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Tips for Preventing Ford EcoBoost Engine Problems
To prevent common problems with Ford EcoBoost engines and ensure their longevity, several critical maintenance practices are recommended:
- Regular Oil and Coolant Checks: Regularly check and top up the oil and coolant levels. Oil leaks are common in EcoBoost engines due to oil seals and gasket failures. Coolant leaks can lead to overheating, which is particularly problematic in models with the 1.0 EcoBoost engine due to a known issue with nylon coolant pipes.
- Intercooler Maintenance: For models like the 3.5 V6, intercooler condensation can lead to engine misfires. Parking the car in a garage and using an intercooler cover can help prevent this issue in cold climates.
- Turbocharger Care: Turbocharger failures are often linked to oil leaks. Maintaining the turbocharger involves regular oil changes and quality filters to prevent failures and preserve engine power.
- Spark Plug and Ignition Coil Maintenance: Regular maintenance and the use of high-quality spark plugs can minimize ignition issues, including misfires and spark plug fouling. Spark plugs in these engines can wear out or get fouled by oil or carbon deposits.
- Timing Chain Inspection: Some EcoBoost engines have issues with timing chain wear. Regular checks and using high-quality oil can help minimize this risk.
- Routine Inspections and Preventive Maintenance: Regular engine inspections can catch issues early. Look for signs of oil or coolant leaks, listen for unusual noises, and address any problems promptly to prevent further damage.
- Addressing Software and Mechanical Updates: Keep the engine’s software updated and consider mechanical upgrades like a redesigned intercooler or a cold air intake system for improved performance and reliability .
Dealing With the Ford 3.5L Engine Problems
Many of the issues listed on this page can be caught if you are mechanically savvy and know what to listen for when test driving a vehicle equipped with this engine. For the rest of us, get a pre-purchase inspection from a local mechanic.
Most mechanics offer inspections for vehicles that include a complete visual examination and full diagnostic. That pesky timing chain or misfiring cylinder might be missed during a test drive but will be found during a pre-purchase inspection.
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