Maximzing Your Ford EcoBoost: Essential Performance Upgrades

Following the GFC of 2008, Ford completely rehauled its model lineup, scraping old models and introducing a new line of EcoBoost engines. These were downsized, turbocharged powerplants with comparable power to larger, aspirated V8s. The main difference though was efficiency. The new engines consumed considerably less fuel but supplied all their torque lower down the rev range. As a result, cars had better acceleration, higher top speeds, and were more fun to drive.

The EcoBoost engines have seen multiple reiterations since their introduction, each with subtle improvements and more power. Today, they’re standard in popular models ranging from the Mustang to the F-150. The 2.3. 2.7 and 3.5-litre engines have proven the most capable, delivering 315, 325 and 400 HP, and 350, 400 and 500 pounds-foot torque respectively. Tuned variants, such as the twin-turbo 3.5 litre V6 in the F-150 offer better pulling power, more towing capacity, higher top speeds, and faster 0-60 times than the thirstier and bigger 5.0 litre V8.

The question remains, can you get more? The aftermarket hasn’t been idle, and now there are various top-notch EcoBoost performance parts for even more driving pleasure. Consider uprated intercoolers paired with modded blow-off valves to get more out of the turbos, reworked performance air intakes to push more air in for combustion, and wider and straighter exhaust tubing to let the engine breathe.

Replace the Stock Intercooler

Intercoolers are exclusive to turbocharged and supercharged engines, where they help increase engine efficiency and output by cooling down the hot, compressed air before it makes its way to the combustion chamber. Hot air enters the intercooler, passes through the fins, and exchanges excess heat to surrounding air. The stock intercooler on the 2.7 and 3.5 litre EcoBoost engines failed due to insufficient size and subpar build, impacting air temperature, density and efficiency.

Replacement EcoBoost performance parts are considerably bigger, some with a 70 per cent larger core than stock variants, considerably wider inlet and outlet tubing, and aluminium hot-side and cast cold-side piping for increased durability, TIG welding ensures integrity under stress, while cast end tanks provide maximum airflow in and out for faster, more efficient spooling and higher horsepower and torque numbers.

Aftermarket intercooler kits are bolt-on designs, so easy to install without needing further modifications. Specifically for the F-150, some variants relocate the intercooler higher in the engine bay, while providing space for aftermarket winches or bigger bumper kits.

Add an Aftermarket Air Intake

The second generation 2.7-litre EcoBoost engine from 2018 and a staple in the F-150 came with significant improvements, including ported fuel injection, a lighter camshaft, and an electronically controlled wastegate for improved turbo performance. This boosted power delivery with more torque earlier on, and reduced wear. For more power, you’ll also be looking at a performance cold air intake.

The combination of bigger and more efficient cone filters, wider intake tubing, and efficient heat shields maximizes airflow, with some designs boasting up to 60 per cent higher air volume than stock figures. Reworded layouts also help with airflow velocity and improved angles for crisper throttle response. You can get the same benefits in the 3.5-litre engine, as well as the inline 2.3-litre and 5-litre V8 in the Mustang, among other vehicles.

The main purpose of an aftermarket intake is to open up the engine. You get a deeper, full-bodied sound, better filtering, improved consumption numbers and reusable filters. So besides the power gains, these EcoBoost performance parts also help with engine longevity and save you cash, with fewer visits to the gas station and lower maintenance needs.

Slap on a New Exhaust

EcoBoost engines can also do with an aftermarket exhaust, especially if you’re pairing this with an updated intake system. The wider tubing helps with combustion efficiency, getting more power down to the wheels and reducing wear in cams, outlet valves, and the EGR system. For the F-150 go with 3″ tubing made of TIG-welded, high-grade stainless steel, paired with high-flow catalytic converters.

The setup improves exhaust velocity, increases scavenging throughout the system, and adds horsepower. Superior mandrel bending ensures uniformity and consistent performance through the entire rev range, while better materials and coatings prevent ruptures and rusting. Similar systems are offered for the Bronco with the 2.3 and 2.7-litre engines.

For the Mustang and Focus RS, consider wider-tube downpipes for improved airflow, and a deeper exhaust sound. You can also add a reworked cat-back system in a Y-pipe layout, with dual tips, racing mufflers and high-grade stainless steel for durability.

Extend Turbo Longevity With Blow-Off Valves

In worst-case scenarios, increased boost pressure into the engine can rip out the turbine impellers and destroy the engine. In most cases, and at lower RPMs, it eats into the performance of the turbo, while increasing wear in other parts. Trapped air from a fast-spooling turbine requires a blow-off valve. This vents built-up air pressure in the atmosphere, maintaining turbo performance and preventing loss of power.

Aftermarket valves are better built with sealed designs and superior materials (such as billet aluminum) than what’s in stock parts. Moreover, they reduce turbocharger and wastegate stress, sustain higher boost pressure (for higher torque and HP numbers), prevent turbo lag for quicker acceleration and are straightforward to install. Lastly, high-pressure solenoids and electronics provide optimized control when you’re on the gas, with a sportier engine sound to round out the package.