Gap between Intercooler & fuse box

[Garry T]

Me again. I have noticed that the gap between the intercooler charge box and fuse box is extremely small. Possibly intercooler charge box is just touching the fuse box. Doesn't appear to be any excessive movement or free play in the intercooler box. Can I assume this is pretty standard.

[Garry T]

My bad. I meant to say that the charge cooler box leans in towards the fuse box at the top, not the whole unit. Hope that makes more sense.

[BartFRS]

Although it’s pretty tight there, the chargecooler shouldn’t lean towards the fuse box.
The chargecooler sits in rubber bushes, maybe they are worn or bolts got loose?

[DanT404]

As Bart says, the chargecooler bushes are possibly worn or it is not located correctly. (quite common, in fact powerflex make uprated poly ones for this application, its usually accompanied by a noise as well)

[Garry T]

Thanks guys, I will have a look. Bet its a pig to get at the fixings.

[WRCmechanic]

That's normal. Even with new Intercooler bushes I had this problem.
But I removed the Intercooler and installed a rubber. That prevent the intercooler rubbing against the fuse box.

[Garry T]

Thats interesting

Thank you for taking the time to post this.
Much appreciated.

[Shaz]

I had the same issue- upon removal I found the bracket attached to the underside of the charge cooler box with allen bolts was bent. (The bracket has the 3 studs that go into the bushes in the transmission upper mount)

I removed, straightened and bolted back the bracket. It has been perfect since then.

My theory is that over the years owners/mechanics leaning into the engine bay place their hand on the charge cooler for support and this gradually deforms the thin bracket resulting in contact with the fuse box.

[Shaz]

One other thing- the bushes were perished and I replaced them with standard rubber ones from the air filter housing on a Focus MK1 diesel- exactly the same part.

I did not want to use Polyurethane bushes as whilst they are great for reducing compliance in suspension components, you actually want a bit of ‘give’ under the charge cooler to stop vibration being transmitted to the body and into the cabin.

[Garry T]

Cheers Shaz, all noted.