F-150 EcoBoost Issues - CAC, Spark Plug, etc

[93Cobra]

A couple tips:
1) change spark plugs right away. Use only Motorcraft SP534 and gdp to .028.
2) drill the weep hole in the lower, driver side of the intercooler. It is always positive pressure, so it will always blow out the condensate.
You will ask why... So, as you research this f150 ecoboost, you will find misfire / stutter stories all over the place. The reason is the intercooler is too efficient and created condensate in it. That condensate gets sucked up under acceleration and blows out spark causing the misfire/stutter. The weep hole allows it to escape before reaching the plugs. Now, in some cases, there was enough condensate to hydrolock the engine. If this issue persists and you survive the misfire episodes (these are very dangerous), you will most likely burn out downstream components (cats and O2 sensors).

Next, always pay attention to every cold start and listen for a rattle. The timing chains and cam phasers have issues.

Ford doesn't have a true fix for any of this... I have lived through it... Awful.

 

[FracaSHO]

A couple tips:
1) change spark plugs right away. Use only Motorcraft SP534 and gdp to .028.
2) drill the weep hole in the lower, driver side of the intercooler. It is always positive pressure, so it will always blow out the condensate.
You will ask why... So, as you research this f150 ecoboost, you will find misfire / stutter stories all over the place. The reason is the intercooler is too efficient and created condensate in it. That condensate gets sucked up under acceleration and blows out spark causing the misfire/stutter. The weep hole allows it to escape before reaching the plugs. Now, in some cases, there was enough condensate to hydrolock the engine. If this issue persists and you survive the misfire episodes (these are very dangerous), you will most likely burn out downstream components (cats and O2 sensors).

Next, always pay attention to every cold start and listen for a rattle. The timing chains and cam phasers have issues.

Ford doesn't have a true fix for any of this... I have lived through it... Awful.

Is there a how-to or pics to help me with the weep hole? Not exactly sure what to do and where it should go. Much appreciated.


Brad
Former SHO Owner
Ecobooster 4 Life

 

[ajpturbo]

You will have an oily mess in and around your truck around the new weep hole in addition to a whistle that wont stop and a boost leak once the hole is drilled

 

[ajpturbo]

Ford doesn't have a true fix for any of this... I have lived through it... Awful.

Sure they do...its called allowable wheel torque error..they changed the value in the new calibrations

The root problem was fords torque based logic for torque delivery via the drive by wire throttle and the fact that it was too sensitive....when the driver demanded torque wasnt achieved as measured by the logic in the ecu it would go into reduced power mode temporarily

So raising the allowable wheels torque error scalar in the tune all that jazz and hesitation and stumbling got eliminated 

 

[SHOdded]

Didn't they also shield part of the intercooler as an attempeted fix?
http://www.f150forum.com/f70/there-fix-condensation-build-up-intercooler-156900/#post1771829

Ford just came out with a TSB today 12-6-4 to reprogram the PCM/TCM to latest level, installed a deflector shield on the intercooler and possibly replace the drivers side catalytic convertor if needed.

FORD:
2011-2012 F-150

ISSUE:

Some 2011-2012 F-150 vehicles built on or before 5/24/2012 and equipped with a 3.5L gasoline turbocharged direct injection (GTDI) Ecoboost engine exhibit a steady or flashing malfunction indicator lamp (MIL) with various diagnostic trouble codes (DTC) and drivability concerns.
ACTION:

Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE



The calibration update contains improvement actions and enhancements to address the following conditions: •Intermittent stumble and/or misfire on hard acceleration after an extended drive at highway speeds being more noticeable during humid or damp conditions.
•Intermittent engine surge during moderate to light loads at cruise.
•Powertrain control module (PCM) Misfire DTC P030x.
•PCM DTC P0430 and/or P0299.
NOTE:INSURE ALL HARD FAULT POWERTRAIN DTCS ARE ADDRESSED PRIOR TO PERFORMING THE CALIBRATION UPDATE.1.Check for DTC P0430. Is DTC P0430 present?1.Yes - Replace the left bank catalytic converter assembly. Refer to Workshop Manual (WSM), Section 309-00. Proceed to Step 2.
2.No - Proceed to Step 2.

2.Is the Charge Air Cooler (CAC) equipped with an air deflector plate? (Figure 1A)

Click the image to open in full size.
Figure 1 - Article 12-6-41.Yes - Proceed to Step 4.
2.No - Proceed to Step 3.

3.Install CAC air deflector plate with two new push pins. (Figure 1B) Proceed to step 4.
4.Reprogram the PCM to the latest calibration using IDS release 79.02A or higher. This new calibration is not included in the 2012.5 DVD. Calibration files may also be obtained at www.motorcraft.com.
NOTELEASE ADVISE THE CUSTOMER THAT THIS VEHICLE IS EQUIPPED WITH AN ADAPTIVE TRANSMISSION SHIFT STRATEGY WHICH ALLOWS THE VEHICLE'S COMPUTER TO LEARN THE TRANSMISSION'S UNIQUE PARAMETERS AND IMPROVE SHIFT QUALITY. WHEN THE ADAPTIVE STRATEGY IS RESET, THE COMPUTER WILL BEGIN A RE-LEARNING PROCESS. THIS RE-LEARNING PROCESS MAY RESULT IN FIRMER THAN NORMAL UPSHIFTS AND DOWNSHIFTS FOR SEVERAL DAYS.
PART NUMBERPART NAMEBL3Z-5E212-ECatalytic Converter AssemblyW520514-S440Nuts (2 Req)CL3Z-19E672-ADeflector PlateW711281-S300Push Pin (2 Req)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.
OPERATIONDESCRIPTIONTIME120604A2011-2012 F-150 3.5L GTDI: Check DTCs, Install CAC Air Deflector Plate if Necessary And Reprogram The PCM (Do Not Use With Any Other Labor Operations)0.5 Hr.120604B2011-2012 F-150 3.5L GTDI: Check DTCs, Replace The Left Catalytic Converter, Install CAC Air Deflector Plate if Necessary And Reprogram The PCM (Do Not Use With Any Other Labor Operations)1.0 Hr.
DEALER CODING

BASIC PART NO.CONDITION CODE5E212 (OPERATION B)126K775 (OPERATION A)42
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford or Lincoln dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
Copyright © 2012 Ford Motor Company

 

[93Cobra]

A couple tips:
1) change spark plugs right away. Use only Motorcraft SP534 and gdp to .028.
2) drill the weep hole in the lower, driver side of the intercooler. It is always positive pressure, so it will always blow out the condensate.
You will ask why... So, as you research this f150 ecoboost, you will find misfire / stutter stories all over the place. The reason is the intercooler is too efficient and created condensate in it. That condensate gets sucked up under acceleration and blows out spark causing the misfire/stutter. The weep hole allows it to escape before reaching the plugs. Now, in some cases, there was enough condensate to hydrolock the engine. If this issue persists and you survive the misfire episodes (these are very dangerous), you will most likely burn out downstream components (cats and O2 sensors).

Next, always pay attention to every cold start and listen for a rattle. The timing chains and cam phasers have issues.

Ford doesn't have a true fix for any of this... I have lived through it... Awful.

Is there a how-to or pics to help me with the weep hole? Not exactly sure what to do and where it should go. Much appreciated.


Brad
Former SHO Owner
Ecobooster 4 Life

Here is all the information you need on this:
http://www.f150ecoboost.net/forum/14-f150-ecoboost-maintenance/9100-pee-hole-my-cac.html

 

[93Cobra]

Ford doesn't have a true fix for any of this... I have lived through it... Awful.

Sure they do...its called allowable wheel torque error..they changed the value in the new calibrations

The root problem was fords torque based logic for torque delivery via the drive by wire throttle and the fact that it was too sensitive....when the driver demanded torque wasnt achieved as measured by the logic in the ecu it would go into reduced power mode temporarily

So raising the allowable wheels torque error scalar in the tune all that jazz and hesitation and stumbling got eliminated

This is completely wrong. On the condensate stutter, you will get a code that shows cylinder misfire. New plugs properly gapped to .028 and the intercooler 1/16" weep hole are the only known fixes. The root cause of this issue is the condensate buildup. Can't stop it from forming, so the hole lets it get out.

The weep hole causes no performance or reliability issues. Folks have run this for 4+ years and no problem from it. They also reported no more stutter events. There is an absolute ton of info out there on how this works and how the hole doesn't create boost loss or whistle.

 

[ajpturbo]

Kinda makes you wonder why ford doesnt drill holes...all intercoolers will have condensate...the problem is the logic ford uses...which is why they used a calibration to update and fix...im sorry you dont understand torque based tuning..but the drilling will work just as turning up the radio will hide noises your car makes.....just have to ask yourself which method of fixing you prefer lol...i know what i pick

 

[SHOdded]

AJ, if the hole is drilled for a plug for regular manual emptying, would that be OK?

 

[ajpturbo]

AJ, if the hole is drilled for a plug for regular manual emptying, would that be OK?

I would do that

 

[93Cobra]

Kinda makes you wonder why ford doesnt drill holes...all intercoolers will have condensate...the problem is the logic ford uses...which is why they used a calibration to update and fix...im sorry you dont understand torque based tuning..but the drilling will work just as turning up the radio will hide noises your car makes.....just have to ask yourself which method of fixing you prefer lol...i know what i pick

This is quite simple to understand. By having the weep hole, you get rug of the moisture buildup AND the oil that flows through there as well. This would never pass the EPA, so no hole from the factory.

The 'fix' Ford had was to add plates to the intercooler, and adjust computer tuning. The idea was to make it less efficient. This path still didn't work and customers complained about the loss of performance/drivability. Many ripped the plate off and went aftermatket tune.

The root cause of the stutter / misfire is condensate blowing out spark. I am not sure what you are missing. This "wheel torque" setting doesn't have anything to do with misfires. There is so much research surrounding all of this that you need to read up on. The transverse mounted engines have less trouble because the intercooler is not efficient in its location. Also, look at 2015+ f150 ecoboosts... The front license plate covers the intercooler for a reason.

 

[93Cobra]

AJ, if the hole is drilled for a plug for regular manual emptying, would that be OK?

I would NEVER plug that hole. You never know when you are going to build condensate, and that one time you floor it and get the misfire. You don't want to say at that moment before the crash "gee, wish i had drained the intercooler". Leave the hole open - causes no harm and protects you.

 

[ajpturbo]

Allowable wheel torque error is the tolerance for measured torque by the ecu which is what triggers a percieved misfire...the lack of torque measured by the crank position sensor and rate of acceleration of the tone ring is crossed referenced with tables in the calibration....when they dont match a percieved misfire is recorded....the changes in the calibration affect that tolerance ....they dont detune the truck

Have you ever wondered why people that add bigger more efficient intercoolers dont have this problem?...its the torque based tuning logic that ford employs...im sorry you are unaware of the tuning aspects and are led by a forum of truck owners that seem to be a class of less technical people

 

[SHOdded]

ok, guys, I think we have reached an impasse here.  let's go back to our corners and find something else fun to talk about

 

[93Cobra]

Allowable wheel torque error is the tolerance for measured torque by the ecu which is what triggers a percieved misfire...the lack of torque measured by the crank position sensor and rate of acceleration of the tone ring is crossed referenced with tables in the calibration....when they dont match a percieved misfire is recorded....the changes in the calibration affect that tolerance ....they dont detune the truck

Have you ever wondered why people that add bigger more efficient intercoolers dont have this problem?...its the torque based tuning logic that ford employs...im sorry you are unaware of the tuning aspects and are led by a forum of truck owners that seem to be a class of less technical people

Actually, the people that add more efficient intercoolers DO have the condensate issue too! The intercooler makers are now devising ways to let it out. For most, they just drill the hole in the aftermarket cooler.

Back to your tuning point. The folks that got the upgraded tune via the tsb STILL had condensate and misfire issues. The root cause is the condensate.

 

[SHOdded]

I think I made myself perfectly clear in my last post.  MOVE ALONG, GUYS!!!

 

[sholxgt]

After using random plumbing parts, tubing, the catch can from a brake bleeder kit, and an old vacuum cleaner this weekend to evacuate the oil from my intercooler, I do wish there was a more convenient method for cleaning the thing.

Seems a petcock drain would come in handy.

I just couldn't bring myself to create a permanent boost leak though.  I totally appreciate that it solves this one problem, it seems it would come at the cost of permanently overworking the turbos to reach the desired torque level.

Sorry SHOdded. Replied while you were typing the other message.  Seems there should probably be a discussion on the topic.  Just maybe not here.

 

[r1crusher]

This "condensate" issue only effected '10-'12 F-150's and the fix was put into production starting with the '13 model year.  Currently having in my driveway a '13 F-150 I can tell you that I have NEVER had any misfire/condensate/etc. issues whatsoever.  I don't believe there is ANY reason to drill holes in '13+ models...which Brad (aka FracaSHO) is the owner of.

I don't want to stir this pot more than it already has been, but I own an F-150 and would never do as suggested.

 

[ZSHO]

I would Emphasize to keep your discussions based on factual information,data and not solely based on speculation and should truly respect SHOdded opinion,position on the matter. Z

 

[r1crusher]

I completely understand, but I thought I'd post up because I can make such claims as I own a model truck in question.  No redistribution of topics from other places or the like.  Just plain truth with my personal ownership.  I do have friends with EB F-150's and could speak on their ownership but it's not as conducive to the discussion whether it's good or bad.

Just like the saying goes....if it ain't broke, don't fix it.