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Drilled the intercooler drain 2011 F150 Ecoboost, #4759060
05/16/18 06:23 PM
05/16/18 06:23 PM
Joined: Feb 2003
Posts: 7,530
Jupiter, Florida
Cujet Offline OP
Cujet  Offline OP
Joined: Feb 2003
Posts: 7,530
Jupiter, Florida
I drive a 2011 F150 SuperCrew with the 3.5L Ecoboost setup. From early on, the engine would misfire horribly when floored, after a drive in the rain. The reason is that the intercooler would condense the moisture in the air, and water would accumulate in large quantities. Only to be forced into the engine under high power. I learned to slowly ease up to full throttle, to clear out the condensed water that accumulated in the intercooler.

I had considered drilling a hole for quite some time now, but never got around to it. Finally did it, and what a pleasant difference! No more misfire and uneven acceleration. The truck is smooth as silk now, and I am quite happy with the result.

Clearly, a 1/16th inch hole is a minor boost leak, but it does not seem to affect the output or boost levels at any point in RPM or throttle position. Probably the hole is small enough to not be a factor.

Here in South Florida, the intercooler condensate is a huge issue.



People who count on their fingers should maintain a discreet silence.
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759066
05/16/18 06:26 PM
05/16/18 06:26 PM
Joined: Apr 2012
Posts: 9,565
Kendall, FL
wemay Offline
wemay  Offline
Joined: Apr 2012
Posts: 9,565
Kendall, FL
Very nice work! Thanks for the vid too. One of my neighbors' Explorer surfers this exact thing. I'll pass on the information.


'18 Sportage LX AWD Pennzoil HM 5w20
'13 Santa Fe Sport 2.0T Castrol GTX Magnatec 5w30
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759068
05/16/18 06:27 PM
05/16/18 06:27 PM
Joined: Jul 2010
Posts: 18,941
PNW
ZeeOSix Offline
ZeeOSix  Offline
Joined: Jul 2010
Posts: 18,941
PNW
Wow, that's a lot of water trapped inside the IC. What's Ford's fix for this water collecting issue?

Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: ZeeOSix] #4759082
05/16/18 06:38 PM
05/16/18 06:38 PM
Joined: Jan 2011
Posts: 569
Anaheim, CA
zorobabel Offline
zorobabel  Offline
Joined: Jan 2011
Posts: 569
Anaheim, CA
Originally Posted By: ZeeOSix
Wow, that's a lot of water trapped inside the IC. What's Ford's fix for this water collecting issue?

Thats a minor prostate issue...
Ford calls it the the carbon cleaning feature.


1997 Maxima 188k, Edge 10w30, K&N HP-1003
2004 Corolla 193k, VWB 5w20 + SSS 10w40, MGL4967
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: zorobabel] #4759097
05/16/18 06:49 PM
05/16/18 06:49 PM
Joined: Jun 2005
Posts: 11,409
Santa Barbara, CA
bdcardinal Offline
bdcardinal  Offline
Joined: Jun 2005
Posts: 11,409
Santa Barbara, CA
Originally Posted By: zorobabel
Originally Posted By: ZeeOSix
Wow, that's a lot of water trapped inside the IC. What's Ford's fix for this water collecting issue?

Thats a minor prostate issue...
Ford calls it the the carbon cleaning feature.


And this is why you don't see carbon buildup as much on them LOL


2014 Ford Mustang GT Track Pack
1995 Ford Mustang GT

Ford/Mazda Parts Counter
NRA Benefactor Member
Opinions expressed are my own.
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759099
05/16/18 06:49 PM
05/16/18 06:49 PM
Joined: Feb 2003
Posts: 7,530
Jupiter, Florida
Cujet Offline OP
Cujet  Offline OP
Joined: Feb 2003
Posts: 7,530
Jupiter, Florida
Ford has a fix that includes blocking off a good portion of the ambient airflow to the intercooler. That seems like a terrible idea to me, as the intercooler is there to cool and can only be effective if there is effective heat exchange.

Sorry, that's not my video. It's the one that inspired me to drill the hole.

I absolutely could not believe how much gunk came out. Seemed like about 10 ounces of brown colored oil/water mix.


People who count on their fingers should maintain a discreet silence.
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759102
05/16/18 06:57 PM
05/16/18 06:57 PM
Joined: Jun 2005
Posts: 11,409
Santa Barbara, CA
bdcardinal Offline
bdcardinal  Offline
Joined: Jun 2005
Posts: 11,409
Santa Barbara, CA
Originally Posted By: Cujet
Ford has a fix that includes blocking off a good portion of the ambient airflow to the intercooler. That seems like a terrible idea to me, as the intercooler is there to cool and can only be effective if there is effective heat exchange.

Sorry, that's not my video. It's the one that inspired me to drill the hole.

I absolutely could not believe how much gunk came out. Seemed like about 10 ounces of brown colored oil/water mix.


Would be nice if there was a drain plug, but you know, that would make sense.


2014 Ford Mustang GT Track Pack
1995 Ford Mustang GT

Ford/Mazda Parts Counter
NRA Benefactor Member
Opinions expressed are my own.
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759114
05/16/18 07:06 PM
05/16/18 07:06 PM
Joined: Apr 2005
Posts: 2,090
Easton, PA
Thermo1223 Offline
Thermo1223  Offline
Joined: Apr 2005
Posts: 2,090
Easton, PA
Was known issue on the newer commonrail VW TDI's as well.



Some would even turn to a solid chunk of ice in the winter and block the intake completely. I've noticed my Tiguan hesitating on damp mornings especially when the dew point hits. The intercooler on the Tiguan is a huge front mount so I bet water is pooling in there too.


2016 VW Tiguan
2013 Ford Fiesta
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759121
05/16/18 07:15 PM
05/16/18 07:15 PM
Joined: Jun 2006
Posts: 5,034
Great White North.. eh
webfors Offline
webfors  Offline
Joined: Jun 2006
Posts: 5,034
Great White North.. eh
Wow, never would have thought. That must be an issue with all intercooler setups to varying degrees!


17 Cadillac ATS 2.0T, Edge D1G2 5w30, XG10575
17 Dodge GC, VWB 5w20, Fram DL11665
15 DL650, Rotella T6 5w40, KN-138
Small engines; RT5 10w30
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759122
05/16/18 07:16 PM
05/16/18 07:16 PM
Joined: Nov 2011
Posts: 1,107
Lyndhurst NJ
Audios Offline
Audios  Offline
Joined: Nov 2011
Posts: 1,107
Lyndhurst NJ
Youre not going to plug the hole you drilled? You wont get faults for boost pressure deviation?


2002 VW Golf TDI-Mobil 1 5/40 TDT
2007 Mercedes GL320 CDI Fuchs 5/40 GT Pro XTL
2005 BMW M3 BMW Twin Power 10/60
2003 BMW M5-Fuchs 5/40
1998 BMW M3/4/5 Fuchs 5/40
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: ZeeOSix] #4759131
05/16/18 07:26 PM
05/16/18 07:26 PM
Joined: Sep 2011
Posts: 3,335
Somewhere
itguy08 Offline
itguy08  Offline
Joined: Sep 2011
Posts: 3,335
Somewhere
Originally Posted By: ZeeOSix
Wow, that's a lot of water trapped inside the IC. What's Ford's fix for this water collecting issue?


They plate off about 1/3 of the intercooler and re-program the PCM. I had it done on mine. No appreciable difference in power, either under load or unloaded. Seems to run fine but we do tow heavy with it so I suppose there isn't much accumulation.

Both methods work well, just depends if you get it done under warranty or not.

The other thing the early Ecoboosts like is new plugs about every 40-50k. Seems to perk up MPGs and makes it slightly smoother.

Last edited by itguy08; 05/16/18 07:33 PM.
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759132
05/16/18 07:27 PM
05/16/18 07:27 PM
Joined: Oct 2010
Posts: 7,033
Michigan
A_Harman Offline
A_Harman  Offline
Joined: Oct 2010
Posts: 7,033
Michigan
Yeah, it's a boost leak, but the turbo just has to run a little faster to pump up the boost to reach the programmed limit. Could add to turbo lag or time to achieve max boost. Have you noticed a difference?


1985 Z51 Corvette track car
2002 Camaro Z28 LS1/6-speed
2001 Dodge Ram 2500 diesel
1972 GMC 1500 shortbed project truck
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759135
05/16/18 07:29 PM
05/16/18 07:29 PM
Joined: Dec 2017
Posts: 413
Massachusetts
VeryNoisyPoet Offline
VeryNoisyPoet  Offline
Joined: Dec 2017
Posts: 413
Massachusetts
Strange that there was no factory measure for getting rid of water. My intercooler came with a little weep hole in the bottom and it always has evidence of ejecting some water and oil when I take off the front air tray.

Same reason why you should have an air chiller and dryer on a shop air compressor.


1998 V70 GLT / 194k miles [10w-30 Valvoline Syn w/ Maxlife Tech + Mann W917 filter]

"Use yah blinkah!"

"Be nice. The alternative involves an air horn and 7000 lumens of high beam."
Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759147
05/16/18 07:38 PM
05/16/18 07:38 PM
Joined: Mar 2008
Posts: 5,873
South Florida
bubbatime Offline
bubbatime  Offline
Joined: Mar 2008
Posts: 5,873
South Florida
Wow that is incredible. Cant believe Ford didn't come up with a factory way to get rid of the water. I guess they don't care up in Michigan, with their much drier air.


17 Chrysler Pacifica Mobil 1 5W30
13 Yamaha XT250 Valv MC 10W40
12 Suzuki S40 Rotella 15W40
10 Acura TSX 2.4 PZL Plat 5W30
06 GMC Sierra Nextgen 10W30


Re: Drilled the intercooler drain 2011 F150 Ecoboost, [Re: Cujet] #4759148
05/16/18 07:39 PM
05/16/18 07:39 PM
Joined: Oct 2011
Posts: 500
maple ridge, bc
2004tdigls Offline
2004tdigls  Offline
Joined: Oct 2011
Posts: 500
maple ridge, bc
this also happened to the new vw tdi engines

they froze solid

http://forums.tdiclub.com/showthread.php?t=302863

or fill up with sludge

http://forums.tdiclub.com/showthread.php?t=374173




Last edited by 2004tdigls; 05/16/18 07:40 PM.
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