As the title suggests, I have a 2015 Mk3 diesel TDCI 2,0L and recently heard a hissing sound with loss of power and then engine warning lights with limp mode.

Finding the culprit was fun, not, but I got there a hole/ crack in the turbo pipe from the right side of the intercooler leading up to the intake manifold.

Thought finding the hole was the hard part but with no listing at GSF or Euro car parts or anything similar on here I ordered a pipe from Amazon which arrived today. Wrong part. I ordered 7G91-6K683-AA but its not correct. Any one help or been here before please?

Possibly this one?

https://ebay.us/m/iqh3ne

having the same with my 2011 only place to get it is fords which is strange as its also a Peugeot and citroen engine is yours the on going to the inlet side of it

Yes still on going, still no part number. The ebay link is unfortunately not the correct pipe.

This is a common vehicle so struggling to understand why this 2.0L TDCI, which as you say is a Euro engine used by a number of manufacturers is neigh on impossible to source a basic part for.

I'm now at the point of chopping up the incorrect new pipe and putting in 51mm ali pipe connectors to get to an approximation of the necessary shape.

Any further advice or even a diagram with a part number would be most welcome.

i found a video on youtube and manged to get a screen shoot of his the old and new the bottom one is new and it seems they have updated as the middle is plastic. the strange thing is you can buy both ends on there own just not the middle have attached photo im also thinking to cut it out and add pipe as it would be the same as the one in this photo but had no way of knowing the pipe size as mine is on the car still

25 minutes ago, Don Miles said:

Any further advice or even a diagram with a part number would be most welcome.

The eBay part was found using a part number from a diagram on the Ford parts catalogue.

Although the 2.0 TDCI engine is common, the intercooler is mounted differently on different models, which explains why this particular pipe is not so easy to find.

Can I confirm that the pipe is on the right hand side of the car (UK drivers side)? As it can get switched when looking at items from the front.

sorry to jump on your post Don

on mine it runs from the front centre of engine across the rad and down just under the drivers side headlight so if sitting in the car its right hand side

this could be it https://www.ebay.co.uk/itm/235061660197?_skw=ford+focus+mk3+2.0+tdci+titanium+x+intercooler+pipe&itmmeta=01KGVZ4VKT8SHTVVR681DEQYYM&hash=item36bac44a25:g:XysAAeSwKQNpLs3m&itmprp=enc%3AAQALAAABEGfYFPkwiKCW4ZNSs2u11xBGSrKk9jtDD41HLL%2FY2jSbEELsKHQE3zuqk0Hncf395oD7z0j%2FCbV5p1qxHNgydL366C5FBpJoBVx7KImJWEJ6QQMxXYzO%2Fe%2BMkJKAnVneXv1CgWQSamXQMr8aIdLsm5MRxpTmT05pDolCjXKuV6fJcPh5jcNnD5DSNnTJeMQj%2BJKDnX4bD4PJ9WWm5H45N6Yr1dnqMJIWhw5f7PhIcNUAJIQk9LT5WXu0z5PIg%2FrqERDRFF2lxwsKGR2TK698vZesC%2FyAKWDb8DOMXkTF4hCSiNPXZb0bLZFFghlSzFIovOjllC8eMpDr%2Btd7bKV1Sohff5%2FHJ2YeTlbuNRPlCEXG%7Ctkp%3ABk9SR5C6k_-GZw

3 hours ago, simon200430 said:

sorry to jump on your post Don

on mine it runs from the front centre of engine across the rad and down just under the drivers side headlight so if sitting in the car its right hand side

Thank you. I was looking at the right pipe...but the wrong model!

I was looking at post 2015 for the OPs car. I now believe it should be pre-2015. In that case, the pipe you linked to is correct. This is the Ford version for comparison.

https://ebay.us/m/vZKkKU

hi tom yes mine is a mk3 2011 not looking forward to changing it when i get round to it looks like the bumper has to come off from what iv found. thank you for your help with the confirmation of the correct part

According to Ford this is the one I need on mine but looks different to the one on there. What a nightmare https://www.ebay.co.uk/itm/393529887999

28 minutes ago, simon200430 said:

According to Ford this is the one I need on mine but looks different to the one on there. What a nightmare https://www.ebay.co.uk/itm/393529887999

That pipe is for Mk3 Focus. Not Mk3 Galaxy.

Bit of a minefield this, Ford parts could not help, so after buying and returning a few different pipes online and returning them I stuck with the 1st style and chopped it in half, added a flanged 51mm Ali joiner . I then fitted it to the intercooler and offered up the original pipe to the TB marking and cutting it accordingly. then off and assembled like in the pic and back on, All good.

Or so I thought. First bit of acceleration and there was a bang; hissing noise was totally back and the dash lit up like a Christmas tree. Guessed I had burst another pipe or my construction had blown to bits. But no what I had done looked good.

Tried taking pictures underneath to see what shape the left pipe was but very difficult to make it out, ordered what I thought it was (it wasnt) I had a look from the top and could see the pipe was a 90 degree bend joining a hard pipe across the back of the intercooler half way before going backwards, but there was clamp loose on the hard pipe. Limped it to the workshop, jacked it up and got underneath in the rain. The rubber bend was off the hard pipe! Fitted the pipe back, tightened the clamp and all is now good. I can only guess that when I had the gearbox rebuild a few months back they didn't tighten the clamp fully but the loss of pressure from the hole meant the pipe stayed put until I stopped the leak; now the loose clamp couldn't hold the pipe on under full pressure, Well thats what I think. So now its onto that annoying rubbing sound and the 70mph juddering.

Ford sell the pipe at 150 which is a total rip off. And have found that they have upgraded it from our full rubber ones to have just rubber elbows and the centre part is plastic. Iv found the correct elbows online for 11 pounds each but no one sells the plastic centre part on its own 🙄. So Iv put an exhaust aluminium bandage over my split to get me out of trouble. Just so I can use the car. But I’m going to buy the top elbow and a peace of Ellie pipe with rolled edges so it doesn’t pop off And do similar to yourself.