Mondeo Mk4 Ac Compressor/Cooling Rad/Condensor Change

Documenting the process for removal and replacement of the ac compressor and cooling pack assembly on a mk4 Mondeo.
This model is a 2.0 Duratec petrol, non turbo but the majority of this video should be applicable to the other models in the range including the diesels.

[@danieldryden4246]

Really helpful video. Thanks for taking the time to make it.

[@NickThornhill]

No worries. Glad people are finding it useful.

[@tripham985]

Great! Helpful video.😍 How does it (both of parts) cost, Sir?

[@NickThornhill]

The AC compressor was £216 The AC condenser was £80 The cooling radiator was £130 The AUX drive belt was £42 All parts were from AUTODOC. Both the radiators and the compressor were made by Nissens. The belt was Gates.

[@tripham985]

@@NickThornhill thanks for the detail.

[@rat-ys6ub]

That's quite a good idea for hose clip. Nice and easy.

[@NickThornhill]

Indeed. Was a pleasant surprise to find something so user friendly.

[@DrewJack-gx2wv]

Thanks mate ? The illustrations are wicked mate , I've subscribed ,👍🏾👍🏾👍🏾👍🏾👍🏾👍🏾

[@NickThornhill]

Thanks. I’ve got a few more general maintenance videos planned on the mondeo. Got the mini to finish first though.

[@DrewJack-gx2wv]

How long did the job take you

[@NickThornhill]

@DrewJack-gx2wv working blind having never done the job before, and having all the parts ready, 1 day. Started early, finished late.

[@DrewJack-gx2wv]

@@NickThornhill you made it look like 2 hour job ? But only because you used the drive on stands

[@NickThornhill]

@DrewJack-gx2wv knowing now what I’m doing, yes probably 2-3 hours next time, although I’m seriously hoping I don’t need to do this again having replaced everything.

[@curtisj2165]

Does the air conditioning work now? I also have the 2.0 petrol and my air conditioning doesn't work

[@NickThornhill]

Yes it does. I did do a proper diagnosis though with a friend who’s qualified. Looked for leaks with UV, etc. He vacuumed tested it and re-gassed it and it was ok for a day or 2 until it started making a whining noise. Usually it’s just a dry seal or a hole in the condenser radiator in the front but the whining noise I had is a sign of a worn pump. And at around 100’000 miles, if it’s been used for that whole time, that’s not uncommon.

[@curtisj2165]

Just had my system pressure tested and a leaking condenser was found. Having your system vacuumed and re-filled is a waste of time and refrigerant unless you find the actual leak first

[@NickThornhill]

Yes but he filled it with UV reactive gas and did a leak check, there were no obvious leaks, no residue, nothing. He was also baffled when it was empty again after a couple of days. This is now a year later and the ac is working fine with the new parts I fitted.

[@curtisj2165]

@@NickThornhill my guy pumped nitrogen into my system and sprayed soapy water over the system's components. There were 5 or 6 tiny holes that wouldn't have been detected by adding dye. As he didn't use any refrigerant the cost of the diagnosis was only £15

[@NickThornhill]

@curtisj2165 nice to have someone with a nitrogen facility local to you. As with most of my stuff I work with what I can and what’s local to me.

[@nickroyal8619]

Thanks for this. -really helpful. Do you think there is any possibility of disconnecting the condenser, and removing it from the rad block without taking the whole rad block out the car (and avoid having to drain rad coolant etc.)?

[@NickThornhill]

Possible, err I’ll give a firm probably, I have done that in my wife’s CMAX and it was a total PITA. My advice is, for the sake of draining the coolant, with those easy release clips, honestly just drain it. It really wasn’t tricky to refil and get the air out, it mostly self bled. The rest was just squeezing the rad hoses to promote some water movement with the car at idle.

[@nickroyal8619]

Great - I'll take a firm probably!!appreciate the response.

[@NickThornhill]

@nickroyal8619 no worries. Let me know how you got on, in case anyone else wants to try it.

[@hoantran9744]

Great video. Thanks

[@NickThornhill]

You’re welcome

[@hydraflyer]

Do you have to remove everything for just the radiator? If so does this mean you need your Aircon regassed?

[@NickThornhill]

The way they all clip together would make it really challenging to separate them in the car. I know a re-gas for the aircon can be an extra expense but by god taking them all out together will be 100 times easier than trying to drop out just the radiator. Also worth noting that the ac radiator is the first one to get stone chips and any other damage so for a little extra cost, it could be worth doing as I did and replacing both rads happy in the knowledge that you can leave the whole area alone for a few more years.

[@hydraflyer]

​@@NickThornhillMy radiator is leaking but the Aircon is absolutely fine. I'm hoping to just get the radiator and fan out and leave the condenser inside, otherwise I need to get the aircon drained and that'll be money down the drain!

[@NickThornhill]

I have done it before with a CMAX. It’s tricky though and you’ll need some height like I had for this to be able to do it. Remember that they lock together and will need separating.

[@rhendersbee685]

Excellent, ta

[@NickThornhill]

You’re welcome.

[@kubarr33]

No need to remove radiator🤣

[@NickThornhill]

Maybe not, I was told it’s possible to do without removing them on a diesel but I didn’t see how those long bolts were going to come out without taking them out. Also I was advised that since I was replacing the pump, that the condenser would be a good thing to change while I was there to make sure all physical parts were new and unlikely to cause further issues