Is this ecoboom?

[Skye]

The problem is bad enough, idling should be generating large amounts of oil. I wouldn't go on any more test drives, for fear enough liquid in one cylinder would cause physical damage to the piston, block or crank. The engine might still be recoverable.

So before the head gasket replacement, cylinder #2 had a loss of 98% of initial pressure. Afterwards, that cylinder and the others were normal (zero-to-little loss of pressure). Check.

But the original problem, huge intake of oil, continued.

As others have mentioned, the turbo itself might be the culprit, emptying large amounts of oil into the intake. Cylinder #2 was an unfortunate casualty.

No one has disconnected and inspected the turbo and intake assemblies yet? I would have thought that'd be accomplished when the head gasket was replaced.

Edit,

But maybe they did, and assumed any oil was a result of the head gasket failure. Thinking the gasket was the culprit, any oil seen in the turbo assembly or intake was coming from cylinder #2, when the cause-and-effect was the other way around: loss of oil from a failed turbo seal drove the head gasket failure.

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[Marko80]

Thank you for your reply...
I have been thinking a lot about possible reasons last few days... I'm not a mechanic, but am (unfortunately) learning about all engine stuff...

I'm now trying to explain whole situation...

It seems that first problem was damage in valve cover gasket, which led to loss of most of engine oil (ingnition coils were swimming in oil), there was also some oil under the car (forgot to write that in the first post).
Since oil level was (to) low, that could cause some troubles for turbo as I have probably driven few hundred km with fault valve cover gasket as there were no sings of oil loss (no warning light despite most of oil missing - Ford engineers can't be proud on that).

After the valve cover gasket was replaced the initial cause for oil loss was solved. However, turbo could already be affected by that initial loss, leading to additional loss of oil (1-1.5L in about 100km) and strange behaviour (partial loss of power, shaking...), but this time there was no oil in ingition coil compartment (I don't know what that part of engine is called). This means, that valve cover gasket issue was solved and oil was probably lost through exhaust.
According to symptoms and his tests the dealer assumed that head gasket is the problem and after the replacement he said (and showed me) that original head gasket was also damaged. Since the problem with strange behaviour and oil loss was still not solved, it all somehow indicates to turbo - it could be the reason for oil loss, poor performance, etc...
The thing that is bothering mechanic (and me) is that after the head gasket replacement and after the test drive there was oil in ignition coil compartment again, despite replaced valve cover gasket. Where did that oil came from???
Other symptoms could be connected to turbo failing, but could also this one be connected?

And one more question regarding failing turbo - below 2000rpm there is poor power, above 3000rpm power is back - does failing turbo cause that kind of behaviour?
If it's not turbo, crack in head or block could be the reason (according to mechanic) - are there any other possibilities?

I would really appreciate all help and further guidance...

 

[Skye]

The thing that is bothering mechanic (and me) is that after the head gasket replacement and after the test drive there was oil in ignition coil compartment again, despite replaced valve cover gasket. Where did that oil came from???

I can think of two reasons. Others with greater Ecoboost or turbo experience could have more.

As a primer for my answers, I'll explain one part of the engine's emissions system, first.

The engine has a Positive Crankcase Ventilation (PCV) system; it's involved in recovering noxious crankcase fumes from the engine.

Combustion gases which pass the piston rings enter the crankcase, the bottom part of the engine where the oil pan is. To remove those, prevent pressure from building and to keep those fumes out of the environment, the PCV system sucks those into the intake system, in an effort to re-burn them.

A PCV valve and tubing connects to the crankcase and the intake via a port in the top of the engine, in the valve cover and coil pack area. In normal operation, crankcase gases travel from the bottom of the engine, through internal drain holes in the engine, to the valve cover area, through the tubing and then into the intake.

Q: How can excess oil enter the engine's intake system, and/or the valve cover and coil pack area?

A1: If the PCV is open all the time, or open at the wrong time, this could draw oil into the intake via the PCV system. Or, if there is an excess amount of pressure building in the crankcase, it's looking for the path of least resistance to escape: the PCV system.

A2: If the turbo is leaking large amounts of oil into the intake, there are two paths for it to take.

A2A: The first is through the intake, into the cylinder, and out the exhaust. But if there is so much oil and pressure

A2B: The oil could return to the intake via the PCV, like in a loop.

While the problem could be a failing or failed PCV valve and system, you're describing large amounts of oil in a very brief period. A lot more than I'd expect than from a bad or failing PCV.

From others' previous comments, it leans towards a failed seal in the turbo.

The PCV valve and system are easy to check. The valve, easy to replace. That system could be checked first. Otherwise, a bad turbo seal leaking large amounts of oil.

More comments will continue to be added, hopefully giving you other potential items to check.

And one more question regarding failing turbo - below 2000rpm there is poor power, above 3000rpm power is back - does failing turbo cause that kind of behaviour?

I wouldn't doubt it. The turbo itself seems to be at least partially working, spinning. A turbo does not provide constant pressure. At lower RPMs, you would have lower amounts of boost and power. As RPM increases, so does boost and power received from the turbo.

 

[luca1290]

And one more question regarding failing turbo - below 2000rpm there is poor power, above 3000rpm power is back - does failing turbo cause that kind of behaviour?
If it's not turbo, crack in head or block could be the reason (according to mechanic) - are there any other possibilities?

Yes. Modern turbocharges have blades that can be adjusted by the ECM so that they are much more responsive and have a higher efficiency range.
It the turbo is damaged and these are not moving, you get these kind of results.

It should not be that difficult to take a look at the turbo, it's just there, on the side of the engine, pop a manifold and see if the shaft moves or the blades show sign of damage.

 

[Buldawg76]

The only way for oil to get into the spark plug cavities on an EcoBoost engine is past the valve cover gasket/plug cavity seals, a failed PCV system will not allow oil into plug cavities. I would suspect possible damage to valve cover gasket/seals if not replaced with new one along with head gasket replacement. It could also have cracks in the head in plug cavities allowing oil to leak in around plugs.

Are all 4 plug cavities filling with oil?

Ecoboosts do not have variable turbo blades/vanes they are fixed so no ECM control possible.

BD

 

[Marko80]

Thank you for your explanations and suggestions... Actually, I hope it is turbo as it seems this should be the cheapest option to repair...

Regarding valve cover gasket - this was the first part that was replaced after ingnition coils were swimming in oil... What is bothering me is that after approx. 100km and loss of substantial amount of oil there was no oil in ignition coil cavity --> meaning initial problem with valve cover was successfully solved.
However, during test drive after head gasket replacement where in only 10-15km considerable amount of oil was lost there was some oil in ignition coil cavity again. The volume was supposedly smaller than in first episode of troubles (I didn't see it, the dealer told me that) --> if valve cover gasket was not a problem, where did this oil come from???

I am waiting for dealer to check the turbo to see if this if the main cause of problems... will get back to you when I have some new info...

 

[Buldawg76]

It could also have a crack in the valve cover in one or more plug cavities.

BD

 

[Marko80]

Despite being just replaced with new one? The dealer didn't replace just the gasket but complete cover as it was not possible to get only gasket...

 

[Buldawg76]

Maybe they did not get all the oil cleaned out from the head gasket replacement.

BD

 

[Marko80]

Maybe they did not get all the oil cleaned out from the head gasket replacement.

BD

They cleaned it after valve cover gasket was replaced, because I checked it myself. However, I didn't see how much oil was there after the test drive, I only know what the dealer told me - there could also be only small volume of oil...

 

[Marko80]

Update: it seems that turbo is the reason. Today the dealer put the turbo apart (by his words) and saw that inner part (blades?) were damaged and some gasket and O-rings are also damaged. I'm going to replace it with refurbished Garret turbocharger... Hopefully this will solve all the troubles and agony of last month and a half...

I will let you know after replacement of the turbocharger...

 

[Wolfys11]

Update: it seems that turbo is the reason. Today the dealer put the turbo apart (by his words) and saw that inner part (blades?) were damaged and some gasket and O-rings are also damaged. I'm going to replace it with refurbished Garret turbocharger... Hopefully this will solve all the troubles and agony of last month and a half...

I will let you know after replacement of the turbocharger...

Im not sure what the stock is but the stock costs 450$ (750 + core charge, give them your turbo as a core return and its only 450$)

Did the swap once myself years ago, maybe it went up by 100$ or whatever

 

[Buldawg76]

Update: it seems that turbo is the reason. Today the dealer put the turbo apart (by his words) and saw that inner part (blades?) were damaged and some gasket and O-rings are also damaged. I'm going to replace it with refurbished Garret turbocharger... Hopefully this will solve all the troubles and agony of last month and a half...

I will let you know after replacement of the turbocharger...

Hopefully none of the blades had broken pieces that got pushed into the IC or worse yet into the cylinders If pieces went thru engine that would not be good at all.

BD

 

[Marko80]

Update: it's not good, not at all
Piston #2 is cracked at the edge of the piston and the cylinder is scratched in one part... I'm totally pissed and disappointed...

I can't believe how many troubles was there and at the end the engine is gone...
Do I only have bad luck and there was sort of wild chain reaction of events that eventually led to engine failure or could this be prevented?

I will try to shortly list all reparis and replacements and would kindly ask for some clarification if this is only some wild coincidence or bad luck:
1. very low engine oil level (below dipstick level) --> there is oil ingnition coils compartment
--> valve cover with gasket was replaced
2. after only about 100km car was not OK and there was loss of substantial amount of oil with no oil in ignition coil cavity
3. After this head gasket was replaced. The dealer said that pistons were perfectly fine when they changed the gasket. I can't check that but I suppose that every dealer checks the pistons and cylinder when head gasket is replaced
4. after head gasket replacement compression was fine, however there was loss of power, white smoke, etc...
5. Afer that dealer checked the turbo and found out that it was damaged on the exhaust side of the turbo --> turbo was replaced
6. After change of turbo they found out that there is full of oil and "grease" in intercooler --> delaer said that this caused increased pressure in the intake system, leading to all troubles
7. When they cleaned everything there were still error codes indicating misfire in cyl #2
8. They checked with camera and said that oil is leaking in cyl#2
9. They tore apart the engine and gave me this sad news

A bit long post, I hope it is understandable... If it is, I would really appreciate some clarification.

 

[Buldawg76]

I cannot say for certain, but it sounds as though it was likely the turbo that went bad first which resulted in the chain of events you had occur due to excessive oil loss and being forced into the IC/intake along with broken pieces of the turbo blades entering #2 cylinder causing piston damage. It's difficult to know for sure exactly which occurred first but I believe the shop you had working on the car did miss some important clues early on that could have possibly prevented some of the damage.

Hope you get it sorted out and fixed or just cut your losses and move on.

BD

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