7 Ford F150 3.5 EcoBoost Engine Problems [Causes & Solutions]

The Ford 3.5 EcoBoost engine is a 3.5-liter V6 gasoline engine that was first introduced in the 2007 Ford Taurus SHO. It is part of Ford’s EcoBoost family of turbocharged, direct-injection gasoline engines, and features twin turbochargers and direct fuel injection. This engine is designed to provide the power of a larger engine while maintaining better fuel efficiency and lower emissions.

The 3.5 EcoBoost engine is used in various Ford models, including the Ford F-150, Ford Expedition, and Lincoln Navigator.

The 3.5 EcoBoost engine features a dual overhead cam (DOHC) design, with four valves per cylinder. The engine block and cylinder heads are made of aluminum to reduce weight and improve thermal efficiency.

The engine also features a variable displacement oil pump and an integrated exhaust manifold to optimize performance and efficiency.

Despite its advanced design and features, the 3.5 EcoBoost engine has had its share of problems.

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7 Ford F150 3.5 EcoBoost Problems

Here are some of the most common problems reported by owners:

1) Carbon Build-Up

One of the most common problems with the 3.5 EcoBoost engine is carbon build-up on the intake valves. This is a common issue with direct injection engines because the fuel is injected directly into the combustion chamber, bypassing the intake valves. This means that the fuel does not help to clean the intake valves, leading to carbon build-up over time. Carbon build-up on the intake valves can lead to a rough idle, loss of power, and poor fuel economy. In extreme cases, it can also lead to engine misfires and damage to the valves and cylinder head.

Cause: This issue is common with direct injection engines because the fuel is injected directly into the combustion chamber, bypassing the intake valves, which means that the fuel does not help to clean the intake valves, leading to carbon build-up over time.

Solution: Regular cleaning of the intake valves using specialized cleaning solutions and equipment can help prevent carbon build-up. Using high-quality fuel with additives that help clean the engine can also help prevent this issue.

2) Intercooler Condensation

Another common problem with the 3.5 EcoBoost engine is condensation build-up in the intercooler. The intercooler is used to cool the compressed air from the turbochargers before it enters the engine. In some cases, moisture can accumulate in the intercooler, leading to a loss of power and poor performance.

In extreme cases, it can also lead to engine misfires and damage to the turbochargers and engine. Ford has issued a technical service bulletin (TSB) for this issue, and the fix usually involves reprogramming the engine control module (ECM) and installing a redesigned intercooler.

Cause: Moisture can accumulate in the intercooler, leading to a loss of power and poor performance. In extreme cases, it can also lead to engine misfires and damage to the turbochargers and engine.

Solution: Reprogramming the engine control module (ECM) and installing a redesigned intercooler can help fix this issue.

3) Ignition Issues

Some owners have reported issues with the ignition system, including misfires and spark plug fouling. The 3.5 EcoBoost engine uses a coil-on-plug ignition system, which means that each cylinder has its own ignition coil and spark plug. Over time, the ignition coils and spark plugs can wear out, leading to misfires and poor performance.

In some cases, the spark plugs can also become fouled with oil or carbon deposits, leading to further issues. Regular maintenance and using high-quality spark plugs can help to minimize this issue.

Cause: Over time, the ignition coils and spark plugs can wear out, leading to misfires and poor performance. In some cases, the spark plugs can also become fouled with oil or carbon deposits, leading to further issues.

Solution: Regular maintenance and using high-quality spark plugs can help to minimize this issue.

4) Timing Chain Wear

Some owners have reported premature timing chain wear, leading to a noisy engine and potential engine damage. The timing chain is used to synchronize the movement of the crankshaft and camshafts, and is a critical component of the engine. Over time, the timing chain can stretch and wear out, leading to changes in the valve timing and potential engine damage.

Regular maintenance and using high-quality oil can help to minimize this issue.

Cause: Over time, the timing chain can stretch and wear out, leading to changes in the valve timing and potential engine damage. Solution: Regular maintenance and using high-quality oil can help to minimize this issue.

5) Turbocharger Failure

The 3.5 EcoBoost engine features twin turbochargers, which can lead to some unique issues. Some owners have reported turbocharger failure, leading to a loss of power and poor performance. The turbochargers are used to increase the air pressure in the intake manifold, which increases the power and torque of the engine.

Over time, the turbochargers can wear out and fail, leading to a loss of power and poor performance. Regular maintenance and using high-quality oil can help to minimize this issue.

Cause: Over time, the turbochargers can wear out and fail, leading to a loss of power and poor performance.

Solution: Regular maintenance and using high-quality oil can help to minimize this issue.

6) Wastegate Issues

Some owners have reported issues with the wastegates, leading to turbocharger over-boost or under-boost conditions. The wastegates are used to control the boost pressure in the intake manifold by bypassing excess exhaust gas around the turbochargers. Over time, the wastegates can wear out and fail, leading to turbocharger over-boost or under boost conditions. Regular maintenance and inspection of the turbochargers and wastegates can help to minimize this issue.

Cause: Over time, the wastegates can wear out and fail, leading to turbocharger over-boost or under-boost conditions.

Solution: Regular maintenance and inspection of the turbochargers and wastegates can help to minimize this issue.

7) Boost Leaks

Some owners have reported boost leaks, leading to a loss of power and poor performance. The boost pressure in the intake manifold is controlled by the turbochargers and wastegates, and any leaks in the system can lead to a loss of power and poor performance. Regular maintenance and inspection of the turbochargers, intercooler, and associated piping can help to minimize this issue.

Cause: Leaks in the system can lead to a loss of power and poor performance.

Solution: Regular maintenance and inspection of the turbochargers, intercooler, and associated piping can help to minimize this issue.

Conclusion

While the Ford 3.5 EcoBoost engine is generally a reliable and robust engine, it does have its share of problems. Regular maintenance and using high-quality oil and filters can help to minimize these issues and extend the life of the engine.

If you own a vehicle with the 3.5 EcoBoost engine, it is important to address any issues as soon as they arise, and to follow the recommended maintenance schedule to ensure a long and trouble-free life for your engine.