Oil Cooler Stat - Changing (TDCi)

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Overview Guide
Ford Model:	Mondeo Mk3
Petrol/Diesel:	Diesel
Estimated Cost:	£21
Difficulty?	Easy/Medium
How long does this take?	40 minutes

How to change a TDCi oil cooler stat without removing the inlet manifold or EGR pipe. This was done on my 2002 115 TDCi but should be very similar on other models.

First of all remove the dipstick and pull off the engine cover if fitted.

Now you will be able to see the inlet manifold with a bracket bolted to it that supports the rubber pipe to the EGR and the wiring for the camshaft sensor.

Follow the rubber vacuum hose on the left to the EGR (just out of picture to the left) and pull the hose from the EGR. Next undo and remove the two 10mm bolts, top right and bottom left to release the bracket from the inlet manifold. Now the whole bracket can be moved to rest out of the way on top of the engine. Be careful not to strain the wiring for the camshaft sensor. Now you will be able to see the oil cooler stat through the space between the metal EGR pipe and the inlet manifold. That’s the part with the hose and clip visible in the centre of the picture.

Now using a long pair of pliers squeeze together and release the clip then pull off the hose. You will loose some coolant at this point. Now you can see the bolt that holds the stat to the water pump.

You are going to need a ¼ drive flexible ratchet to undo the bolt ‘cos there isn’t a lot of room to turn a tool in that space. But it is possible. I used the one in the picture below with the key used to give an idea of the size of ratchet handle needed to get in the space.

Once you’ve got the bolt out carefully pull the thermostat from it’s housing as in the next picture.

The offending article…………

Putting it back together is simply a reversal of the above but smear the rubber ‘O’ ring on the new thermostat with Vaseline to make it easy to push into place. Once it’s all back together you will need to top up the cooling system with a 50/50 mix of the correct coolant from Fords. It will require approx. three and half to four litres of coolant to top it back up so buy two litres of antifreeze to mix 50/50. Once you’ve topped it up give the car a run and check the level again. Don’t remove the cap while the engine is hot.

Job Done.

Should take a competent person about 30-40 minutes.

Part Number for stat is 1128018

Ford will probably tell you need the ‘O’ ring kit part number 1114968. You don’t. The thermostat will come with an ‘O’ ring fitted. This job can be done by removing the inlet manifold and EGR if you want to take the opportunity to clean them out and does give easier access. However, this is the way to do it without taking the manifold off.