This job is easy and only requires minimal tools, but can be messy. Beware the aftermarket units temp to be lower temperature rated and not have the air bleed valve of the original Ford units, so use proper Ford ones. There is also a tendency for thermostats to stick open on Mondeo's
| Difficulty: | |
Required Tools: Mole grips, 10mm Socket, Screw driver, Fresh Antifreeze
mix, instant gasket
Time Required: 1 hour
Parts Required: 1001993 Thermostat Assembly £6.07, 10092262 Seal £1.09
Firstly remove the inlet air resonator so you can actually see what you are doing (better yet buy a K&N 57i kit and remove it permanently). make sure the engine is cold or barely warm. You going to have your fingers in there so you don't want it hot
Above is what you should be seeing. The thermostat housing is the block with the large Bronze sender unit (Fan and EEC temp) and the 3 rubber heater hoses running into it. Remove the Sender units connector and use Mole grips to unclamp the top radiator hose (the big one) and pull it from the housing.
NB you can also clearly see my Earls armoured hoses running to the passenger compartment heater matrix and the metal rubber hose combo running to the Crankcase Breather Valve (PCV) by the red painted block (Red = 2nd stage mods (for competition rules))
OK, it should now look like this and you probably have wet feet!!!!. Beware the old antifreeze mix is slippery and some types are poisonous, so no fingers in mouth and wash it all away afterwards. You can leave on the top this return hose.
Now undo the 3 10mm bolts holding the housing on
And the front cover should come off in your hands
Here is what mine looked like. Note the way the thermostat faces. Pull out the old stat and clean up all the surfaces
The Old Quinton Hazel (Halfords) Stat (on the right) V. the new Ford Stat on the Left. Note the Ford stat has an air bleed valve (Must go at top) and an opening temp on 92 C as opposed to the QH units 88 C. The Ford unit also has a larger valve for more flow
Now put the new Ford gasket onto the big flange of the new stat and insert the stat the right way around into the housing with the air bleed hole at the top. Put a THIN bead of instant gasket in the sealing face of the cover and bolt it back on
Refit the Top radiator hose (give it a good check for leaks) and make sure its seated and clamped properly
Refill the radiator expansion tank with fresh Antifreeze mix. Plug all the connectors back and restart engine. Get engine to full temp and top up fluids as required
This job is easy but awkward and only requires minimal tools, but can be messy
The temperature gauge on the dash has its own sender unit and there is a lot or variation on where each unit indicates on the gauge. Buy 10 units and you'll get 10 different readings. So don't be alarmed if the new unit says different from the old. Also be warned that the wires to this unit are thin and stretched tight and can break. Its common to see the wire fail here resulting in NO temp reading (but the car will run fine, as the Computer uses a different sender unit)
| Difficulty: | |
Required Tools: 22mm Deep Socket, Screw driver, Fresh Antifreeze mix
Time Required: 1 hour
Parts Required: 6193368 Sender Assembly £10.02
Make sure the engine is cold or only slightly warm before starting
As usual take off the induction Plenum, so you can see and access the thermostat housing
Here I have taken off the top radiator hose for extra visibility (I was changing the thermostat at the same time), you can do this job with it in place
Here I have taken off the thermostat cover and you can see the bronze sender unit clearly to the lower middle. You can do this job with the thermostat housing and hoses in place, by feel. Remove the wiring connector from the unit
A deep 22mm socket can be used to reach over the connector onto the bronze barrel to withdraw the sender. Remember that antifreeze will escape when it is removed.
Refit the new unit. Ford have very nicely put sealant on the threads so you don't need any.
Refill the radiator expansion tank with fresh Antifreeze mix. Plug all the connectors back and restart engine. Get engine to full temp and top up fluids as required
Mad Moles Mondeo Madness, © Mad Mole 2001. You may see
the Molemobile fly past in the Sutton area (Surrey).
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