So my 95k mile 2013 FiST has started consuming coolant about a month ago (need to add about a cup or two per day). The engine is completely stock, has had the recall done (80C thermostat, coolant level sensor, etc.) but did require the head to come off in June last year due to a seized spark plug. The head was reconditioned, and piston rings replaced since they were quite sticky. It was driving great for about 5 months after the rebuild.
I've seen enough evidence in my region (and UK forums) that my coolant loss
could be related to the deck deformation which compromises the head gasket in the area between the cylinders. In high-HP cars, the UK guys have seen many block failures due to a cracked liner close to the deck. Pumaspeed have some possible solutions, but its hard to say if it will solve the problem for good.
Ford changed the design of the 2.0 and 1.5 Ecoboost engine blocks to remove the slot between the cylinders after all the failures (the 2.0T history is quite interesting, going from a closed deck, to open-deck, and then back to a semi-closed deck design). But Ford opted to discontinue the 1.6T since most applications moved to the 1.5 Ecoboost, so no new block design is available for the 1.6.
AdamBrunson/TunedPlus(?) was looking at using the 1.5 EB block on the 1.6, since it is virtually identical, but he hasn't posted any updates in over a year.
View: https://youtu.be/O11vR9pwAmg?t=146
. ^^This might be a viable solution if they can work out the details.
When my mechanic opens up again in a week or two I'll have him pull the head and assess the damage. He's also shown me a block which he has resleeved, but I'm not convinced that's the solution either. In the mean time, I bit the bullet and got a 2022 Honda Fit,
.