Ford EcoBoost engine issues

[Gazzzaa]

Some, if not all, of you will be aware of the information here. Bear with me as I correlate the facts and hopefully give you all some useful information. Please note that this information is for petrol engines and NOT diesel engines.

Most of my information is based in the 1.5 litre 4 cylinder EcoBoost, as fitted to the LZ Focus in Australia from about June 2016. This is the car that I drive and was the primary reason for my research. However, my research on the net has also picked up similar problems with the 1.0 litre, 1.6 litre and 2.0 litre engines, the latter 2 being 4 cylinder engines. Anecdotally, the problems may also occur with the 2.3 litre EcoBoost, but I have not researched this personally. I encourage anyone with this engine to do their own research.

As you are aware, Ford EcoBoost Turbo engines have problems, many related to a design fault that allows coolant to leak into (usually) No.1 cylinder. There are temporary fixes for this problem such as head gasket replacement (in my instance) or Ford USA Technical Service Bulletin 19-2139 from November 2019, which is quite comprehensive (7 pages) but is ultimately a fix only. The only permanent solution is an engine replacement with a new engine incorporating a design adjustment to fix the original design fault.

Because these engines sold well overseas, there have been class actions against Ford in the US (see ClassAction.org) the UK (see FordAuthority.com) and only last week in Canada. These engines sold poorly in Australia, so there are not the numbers to really do anything much in Australia.

The problem has existed since approximately 2010 and was finally fixed with the release of newly designed engines in April-May-June of 2019. For example, any 2.0 litre turbo sold in Australia and built on or before 16 May 2019 (Mondeo, Escape, Focus ST) will eventually succumb to this problem.

Ford Australia know that the problem exists but are hoping that it quietly goes away. Let's face it, their marketing efforts were so appalling that they sold relatively few of these engines anyway.

My experience is as follows. In early Feb 2023 it began with a slight 'miss' when accelerating and the engine was running on 3 cylinders within a week. The RACV patrolman picked up no faults with his OBD2 tool, but he suspected a cylinder was out and diagnosed the presence of water in cylinder 1. My local Ford Dealer had been experiencing staffing issues for some time and a lack of mechanics meant that it took two weeks to repair. I was charged $260 for the head gasket to be replaced.

Fast forward to early June and the engine began to 'miss' again. I hadn't driven the car for the entire month of April because I was overseas on holiday. This time I researched the problem extensively on the internet and arrived at the local Ford dealer, armed with an extensive folio of printed material that backed up my assertions. I left the car there on 08 June. I called on 13 June because I had heard nothing and was told that Ford had agreed to replace my engine with a new 'updated' engine as a 'goodwill' gesture. The car was out of warranty but their 'goodwill' extended to 7 years from the build date. I was one month short of this, thankfully.

The next 5 weeks was full of phone calls, visits, emails, text messages etc, all initiated by me, because no-one at the dealership or Ford Australia was updating me on anything. In the middle of this, I suffered a family bereavement, and to top it off, my wife's Ford Kuga broke down with a DPF problem that the dealer could not look at for 4 weeks. We were borrowing cars to get around and still not getting any answers from anyone and, eventually, I blew a fuse. I marched into the Ford dealership, asked to see either the service manager or the dealer principal on 11 June and said that I wasn't leaving until I knew when I was getting my car back.

Long story short, a local diesel specialist fixed the Kuga and he will now get my future business. The original Ford service manager had 'left' in June and his replacement was true to her work and my Focus was back with me, with a new donk, on 18 June.

The total cost to me was $560 for a new manifold and oil/water separator. The $260 from February 2023 was refunded by Ford Australia. At no stage did anyone argue with me about the extent of the problem. Ford Australia and their dealers are aware. Bear in mind the quoted 7 year 'goodwill' period and if you have an affected vehicle, gather as much information as you can and approach your dealer with confidence.

[kevino]

Yes a guy in my townhouse complex had an Lz 1.5 sport. Ford replaced the engine at Ford s cost. He then sold it and on his second Cx 5.

I had an Lz 1.5 manual which I traded in on a Skoda when the Lz reached 129000 motor was ok but it mainly did freeway work

I now have a 2022 Puma with the one litre ecoboost three cyl. I m hoping Ford have changed the engine design to avoid issues.

[VicVic]

Gazzzaa - thanks so much for this comprehensive post. I got the LZ Sport "serviced" whilst my husband was overseas as it started missing. The replaced all coils and sparks and it seemed to be fine. The is started misbehaving again and eventually overheated and was low in coolant. NRMA patrolman diagnosed leaking head gasket, topped up water, we limped it home (no overheating for this short trip) and it was towed to Ford dealer today.

I will be doing the same as you and dropping in a folio of printed material to help them along with the full repair. Thanks again.

[VicVic]

Update from me: all fixed now. Dominelli Ford replaced the full long engine at no cost to me. I was so relieved. And it was so stressful at the time, but Ford were really good about it all. They even gave the hubbie a loan car whilst it was getting done.
Phew!

[samsy351]

Hi guys would like to pm either if you about how you went about getting this issue sorted with Ford
How your experience was and any difficulties etc

[Focus2016]

Hi team, have just come across your posts as my 2016 Focus 1.5 Sport has the same issue. Purchased used from the Ford dealership last August, engine had been misfiring so took it in to Ford service centre turns out it has a cracked head and entire engine needs replaced. Anywho, I’ve read plenty about this being a known issue overseas but not a lot here in Australia. If you guys would be willing to share any info or guidance you have about this issue I would really appreciate it as I’m super stressed and confused about where to go from here as I purchased the Focus used and apparently Ford have said that as I’m not the originally owner they won’t do anything about it. Don’t really know what I’m asking, I guess I’m just venting but if you do have any info that would help I would be grateful! Thanks

[VicVic]

Definitely can be fixed by ford. I was not the original owner of mine either. I would call Ford Australia, tell them what's happened, tell them you know that it has been acknowledged as an issue with this kind of engine in Australia as well as in Canada and the US and ask them to log a case. They'll give you a case number and then when you book it in with your local Ford dealer you give them the case number ring forward back and say listen. I've taken it down to my local dealership. I've given them the case number they going to check it out for me. They'll talk to each other and next thing you'll get a phone call saying that they're going to replace the long engine at no cost but be warned it could take 8 to 12 weeks.

[VicVic]

Sorry, a few little issues with the voice to text there. Essentially what happened with me was that I had exactly the same issue as Gazza. It was missing them overheating . Coolant leaked into the head and eventually caused it to crack. I rang Ford Australia. I got a case number. I rang my local dealer they said bring it down and we'll have a look at it. And gave them the Ford Australia case number and then they spoke to each other and next thing I got a phone call saying it'll be replaced at no cost to you. Ford Australia even supplied a replacement car for the long time that we were awaiting a replacement engine.