Ford Mondeo (petrol engines). Manual - part 90
Warning: Do not disconnect any
of the refrigerant hoses.
5 Unbolt the radiator mounting brackets from
the subframe; note that they are handed, and
are marked to ensure correct refitting (see
illustration). Collect the bottom mounting
rubbers, noting which way up they are fitted,
and store them carefully.
6 Carefully lower the radiator from the
vehicle, and withdraw it.
7 With the radiator removed, it can be
inspected for leaks and damage. If it needs
repair, have a radiator specialist or dealer
service department perform the work, as
special techniques are required.
8 Insects and dirt can be removed from the
radiator with a garden hose or a soft brush.
Don’t bend the cooling fins as this is done.
Refitting
9 Refitting is the reverse of the removal
procedure. Be sure the mounting rubbers are
seated properly at the base of the radiator.
10 After refitting, refill the cooling system
with the proper mixture of antifreeze and
water (see Chapter 1).
11 Start the engine, and check for leaks.
Allow the engine to reach normal operating
temperature, indicated by the radiator top
hose becoming hot. Recheck the coolant
level, and add more if required.
12 If working on an vehicle with automatic
transmission, check and add transmission
fluid as needed (see Chapter 1).
Expansion tank
13 With the engine completely cool, remove
the expansion tank filler cap to release any
pressure, then refit the cap.
14 Disconnect the hoses from the tank,
upper hose first. As each hose is
disconnected, drain the tank’s contents into a
clean container. If the antifreeze is not due for
renewal, the drained coolant may be re-used,
if it is kept clean.
15 Unscrew the tank’s two mounting bolts
and withdraw it, unplugging the coolant low
level switch electrical connector (where fitted).
16 Wash out the tank, and inspect it for
cracks and chafing - renew it if damaged.
17 Refitting is the reverse of the removal
procedure. Refill the cooling system with the
proper mixture of antifreeze and water (see
Chapter 1), then start the engine and allow it
to reach normal operating temperature,
indicated by the radiator top hose becoming
hot. Recheck the coolant level and add more
if required, then check for leaks.
Note: Refer to the warnings given in Section 1
of this Chapter before starting work.
Check
1 A failure in the water pump can cause
serious engine damage due to overheating.
2 There are three ways to check the operation
of the water pump while it’s installed on the
engine. If the pump is defective, it should be
replaced with a new or rebuilt unit.
3 With the engine running at normal operating
temperature, squeeze the radiator top hose. If
the water pump is working properly, a
pressure surge should be felt as the hose is
released.
Warning: Keep your hands away
from the radiator electric
cooling fan blades!
4 Remove the timing belt covers (see Chap-
ter 2, Part A). Water pumps are equipped with
weep or vent holes. If a failure occurs in the
pump seal, coolant will leak from the hole. In
most cases you’ll need an electric torch to
find the hole on the water pump from
underneath to check for leaks.
5 If the water pump shaft bearings fail, there
may be a howling sound at the drivebelt end
of the engine while it’s running. Shaft wear
can be felt if the water pump pulley is rocked
up and down. Don’t mistake drivebelt
slippage, which causes a squealing sound, for
water pump bearing failure.
Removal and refitting
6 Remove the timing belt and tensioner (see
Chapter 2, Part A). As noted in Chapter 2, if
the belt is fouled with coolant, it must be
renewed as a matter of course.
7 Drain the cooling system (see Chapter 1).
8 Disconnect the radiator bottom hose from
the pump union. It is easier to reach this union
if the power steering pump is unbolted and
moved aside as described in Chapter 10 (see
illustration). There is no need to disconnect
any of the power steering system hoses.
9 Unbolt and remove the water pump (see
illustration). If the pump is to be renewed,
unbolt the timing belt guide pulleys, and
transfer them to the new pump.
10 Clean the mating surfaces carefully; the
gasket must be renewed whenever it is
disturbed (see illustration).
11 On refitting, use grease to stick the new
gasket in place, refit the pump, and tighten
the pump bolts to the specified torque wrench
setting.
12 The remainder of the reassembly
procedure is the reverse of dismantling. Note
that a new tensioner spring and retaining pin
must be fitted if the timing belt has been
removed for the first time. Tighten all
fasteners to the specified torque wrench
settings, and refill the system with coolant as
described in Chapter 1.
8 Water pump -
check, removal and refitting
3•6 Cooling, heating and air conditioning systems
7.5 Radiator mounting bracket-to-
subframe bolts (A), air conditioning system
condenser mounting bolt (B)
8.8 Power steering system pump should
be removed to reach water pump hose
union (arrowed)
8.9 Unscrew bolts (arrowed) . . .
8.10 . . . to remove water pump - always
renew gasket and clean all mating
surfaces carefully