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Mk 4 2.0 Diesel Ecoblue Ford Focus Intercooler Coolant Tank

Paul De
Paul De
in Ford Focus Club

Featured Replies

Hi Folks. 
I am no mechanic so please bear with me. 
I have a 2019 Ford Focus 2.0 Ecoblue diesel estate. The car is fantastic and I love it. 
I do have an issue with it and need some help. 
The intercooler coolant tank empties every 2 days following me driving the car. If don’t refill the tank the car goes into limp mode. It has been to 5 garages 2 of whom have done a pressure leak test and they can find no leak even when smoke is used. 
So I  need some help from you experts, what is going on with my car. 
I have attached a pic to show you where I refill every couple of days. 
I can’t be the only one with this issue. 

IMG_0951.jpeg

  • Quote


    You have a Left Hand Drive car in Durham ???

    Here's an easy thing to try. Swap the filler cap from the main expansion tank with the one from the intercooler tank.

    The filler caps are very prone to going faulty and allowing the coolant to escape.

  • Quote
    • Like 1
    • Author
    5 minutes ago, unofix said:

    You have a Left Hand Drive car in Durham ???

    Here's an easy thing to try. Swap the filler cap from the main expansion tank with the one from the intercooler tank.

    The filler caps are very prone to going faulty and allowing the coolant to escape.

    Thank you. It’s an internet pic, it’s raining here so didn’t want to go outside to take it 😉

  • Quote
    • Haha 1

    The intercooler cooling system is very simple.  It's totally separate from the main cooling system.  Only consists of the intercooler itself, the reservoir, and an electric coolant pump.  Then a few pipes to join those parts together.  There really aren't many places that it can leak.  Swapping the cap does sound like the best option for now.

  • Quote
    • 3 weeks later...
    • Author

    Hi All. Just an update to this problem. After much investigation, it was found that once the intercooler was removed it had a crack in it. The leak was dripping onto the exhaust manifold which was hot and therefore the water was evaporating, hence why we could not see any drips etc. New intercooler and all is good.

  • Quote
    • Like 3
    • Thanks 3
    • 4 weeks later...
    On 6/21/2025 at 10:31 PM, Paul De said:

    Hi Folks. 
    I am no mechanic so please bear with me. 
    I have a 2019 Ford Focus 2.0 Ecoblue diesel estate. The car is fantastic and I love it. 
    I do have an issue with it and need some help. 
    The intercooler coolant tank empties every 2 days following me driving the car. If don’t refill the tank the car goes into limp mode. It has been to 5 garages 2 of whom have done a pressure leak test and they can find no leak even when smoke is used. 
    So I  need some help from you experts, what is going on with my car. 
    I have attached a pic to show you where I refill every couple of days. 
    I can’t be the only one with this issue. 

    IMG_0951.jpeg

    Hi Paul   i have the same problem,,   could you tell me how much the replacement cooler cost please ,,  thanks

  • Quote
    • Author

    kevuk20 it was done under warranty, but I think overall it was around £1300-£1400. The part is a ford only part which was about £900 and the allocated garage time is 3 hours labour.

  • Quote

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