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Dave May

Member Since 27 Oct 2013
Offline Last Active Aug 27 2014 08:31 PM

Posts I've Made

In Topic: Mondeo 2.0 Tdi 2004. How To Easily Remove The Alternator And Belt ( Many Phot...

22 August 2014 - 12:48 PM

You have to relieve spring pressure on the drop link so the bolt can be pushed out. Levering downwards is the only way to do that. Try it and you will see it will not damage anything. Obviously levering downwards with the bolts tight will break something.

In Topic: Mondeo Tdci 2004 Flashing Glowplug And Cutting Out When Overtaking. Fixed Now

19 August 2014 - 08:37 PM

I would phone the previous owner and ask where he got the injectors from because it sounds to me like one or more of the injectors have a leaking leakback valve so fuel pressure is reduced in the common fuel rail. Problem is it will cost about £450 to get all four injectors reconditioned as I did. But it did fix my cutout problems. You could do a leakback test on all four injectors, many web sites show how to do this using 4 plastic bottles.


If you look at the injectors you will see the leakback clips. Don't bother to try to take the plastic pipes off these clips as they will leak fuel all over the top of the engine. Go to a breakers yard or a Ford main dealers and purchase four new clips then you can make up a leakback test kit. You will need 4 plastic bottles + 4 new leakback clips + about 6 foot of plastic pipe cut into four 18 inch lengths. This is a standard testing kit they use at the garages. They quickly unclip the leakback pipes then clip on the test kit then start the engine and watch for which bottle fills up first then charge you £100 for doing it. 

In Topic: Mk3 Mondeo Wheel Bearing

05 June 2014 - 03:33 PM

I did mine a few months back.


I found the 4 bolts were jammed solid and rusty, the torx head just rounds off, but it is still very easy to remove the 4 bolts.


Cut the 4 bolt heads off with a small angle grinder ( that only takes 5 mins ), then lever off the old hub, that leaves about 20mm of studs to unscrew.


Using the angle grinder again make a flat on all 4 bolts. Unscrew the bolts using molegrips. Without the flat spots the molegrips will just slip round on the jammed bolts.


Its an easy job and they lasted 130000 miles for me.


I got my 2 rear hubs for my  Mondeo Estate from ebay  £35 each brand new, lots of outlets sell them and free delivery.


Good Luck



In Topic: Mondeo 2.0 Tdi 2004. How To Easily Remove The Alternator And Belt ( Many Phot...

19 March 2014 - 06:20 PM


In Topic: Mondeo 2.0 Tdi 2004. How To Easily Remove The Alternator And Belt ( Many Phot...

04 December 2013 - 09:22 PM

Thanks for the positive feedback Nic, it was good to know my experience of doing the job had helped someone.


Did you manage to make the welded tool for the spring tensioner? The difficult job for me was trying to disconnect the 3 pin plug on the alternator, but after realising where the tab was, it just fell off, no need to force anything. I could now easily change an alternator and belt in less than 2 hours. Best with a ramp and Torx socket though.


You will soon see how the belt is routed. The spring tensioner has two brackets top and bottom bolted onto the engine block. The belt runs over and under the top bracket so is trapped.


These serpentine belts only drive two units, the alternator and the A/C pump ( the water pump has a seperate belt ). I think this belt would have lasted 200,000  miles provided the alternator and A/C pump do not seize up. So you could just let it run until it eventually snaps. The car will still run and not overheat, its just the battery that will gradually go flat and the diesel will run a lot longer than the petrol engine, but join the AA to get you home just incase.


Best Wishes for Christmas everyone.