INVESTIGATIVE REPORT

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REPORT SECTION 03: CHRONOLOGY OF FAILURE

The engineering genesis of the 1.5L EcoBoost (codenamed "Dragon") prioritized thermal efficiency and displacement reduction. Ford engineers introduced high-pressure direct injection systems operating at 2,900–3,600 psi to maximize power output from the three-cylinder block. This design choice created extreme thermal cycling and vibrational stress on fuel delivery components. Between 2016 and 2019, internal testing and early field data indicated structural weaknesses in the aluminum block and cylinder head interface. Early Technical Service Bulletins (TSBs) focused on coolant intrusion, yet these documents also contained the first statistical anomalies regarding fuel odor complaints in pre-production and early fleet models.

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