All about Ford Mondeo

Radiator and expansion tank - removal, inspection and refitting
Cooling, heating, and air conditioning systems / Radiator and expansion tank - removal, inspection and refitting


Note: Refer to the warnings given in Section 1 of this Chapter before starting work.

Radiator
Removal
Note: If leakage is the reason for removing the radiator, bear in mind that minor leaks can often be cured using a radiator sealant with the radiator in situ.

1 Remove the radiator fan and shroud assembly (see Section 5).

2 Disconnect the bottom hose from the radiator.

3 If the vehicle has automatic transmission, disconnect the fluid cooler lines, and plug the lines and fittings.

4 If the vehicle has air conditioning, unscrew the condenser mounting nuts or bolts, detach the condenser from the radiator, and tie it to the engine compartment front crossmember.

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.

7.5 Radiator mounting bracket-tosubframe bolts (A), air conditioning system
7.5 Radiator mounting bracket-tosubframe bolts (A), air conditioning system condenser mounting bolt (B)

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.

DonТt 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 tankТs 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 tankТs 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.


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