Ford Mondeo Workshop Service and Auto Repair Manuals

Disconnect Tool, Spring Lock Coupling 1/2 inch (blue)

412-027 (34-001)

Disconnect Tool, Spring Lock Coupling 5/8 inch (black)

412-038 (34-003)

Remover/Installer, Cooling Hose Clamp

303-397 (24-003)

1. Drain the cooling system. For additional information, refer to: (303-03 Engine Cooling)

   Cooling System Draining, Filling and Bleeding - 1.8L Duratec-HE (MI4)/1.8L Duratec-SCi (MI4)/2.0L Duratec-HE (MI4) (General Procedures),

   Cooling System Draining, Filling and Bleeding - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6) (General Procedures),

   Cooling System Draining, Filling and Bleeding - 2.0L Duratorq-Di/TDDi (Puma) Diesel/2.0L Duratorq-TDCi (Puma) Diesel/2.2L Duratorq-TDCi (Puma) Diesel (General Procedures).

2. Drain the air conditioning system.
   For additional information, refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (412-00 Climate Control System - General Information, General Procedures).
   

3. Raise and support the vehicle. For additional information, refer to: (100-02 Jacking and Lifting)

   Lifting (Description and Operation),

   Lifting - 3.0L Duratec-ST (VE6) (Description and Operation).

4. Remove the engine undershield.

5. Using the special tool, disconnect the coolant hoses from the heater core.
   • Disconnect the water drain hose from the water drain channel.

6. Lower the vehicle.

7. Remove the instrument panel.
   For additional information, refer to: Instrument Panel (501-12 Instrument Panel and Console, Removal and Installation).
   

8. Remove the duct.

9. Detach the right-hand door opening weatherstrip from the A-pillar.

10. Remove the right-hand cowl side trim panel.

11. Remove the ground connection retaining bolts.

12. Disconnect the main body electrical connector.

13. Disconnect the generic electronic module (GEM) electrical connectors.

14. Detach the wiring harness from the heater core and evaporator core housing.

15. Disconnect the vent actuators electrical connectors.
    • Unclip the wiring harness.

16. Disconnect the blower motor and blower motor resistor electrical connectors.

17. Disconnect the temperature sensor electrical connector.

18. Disconnect the parking brake warning light switch electrical connector.

19. Disconnect the adaptive restraint module electrical connectors.
    • Unclip the wiring harness.

20. Disconnect the central junction box (CJB) electrical connectors.

21. Remove the windshield air duct.

22. Remove the in-vehicle crossbeam retaining bolts (right-hand side shown).
    • Remove the blanking caps.

23. Remove the ignition coil.
    For additional information, refer to: Ignition Coil Pack - 2.5L Duratec-VE (VE6) (303-07C Engine Ignition - 2.5L Duratec-VE (VE6)/3.0L Duratec-SE (VE6)/3.0L Duratec-ST (VE6), Removal and Installation).
    

24. Remove the refrigerant line spring lock coupling locking clips.

25. Using the special tool, disconnect the left-hand refrigerant line from the evaporator core.
    • Discard the O-ring seals.

26. Using the special tool, disconnect the right-hand refrigerant line from the evaporator core.
    • Discard the O-ring seals.

27. Remove the heater core and evaporator core housing retaining nut.

28. Remove the in-vehicle crossbeam.
    • Unclip the wiring harness.

29. Remove the heater core and evaporator core housing.

1. 

   NOTE:Install new refrigerant line O-ring seals.
   

   NOTE:Lubricate the refrigerant line O-ring seals with clean refrigerant oil before installation.
   To install, reverse the removal procedure.