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Discussion Starter · #1 ·
Hi All

About a week ago had a loud rattle from my engine bay of my 2001 MK3 Mondeo 1.8 which has done 83.5k miles. Reading on the forum, I thought it was the tensioner and belt to be changed. I bought the items and was about to take it to a garage the next day when the same day, the car won't start. I had a burning smell near the AC compressor area. Now the engine wouldn't turn over even though the starter is clicking (trying to crank the engine).

I think the AC Compressor has sized and jammed which is in turn not allowing the engine to turn over!

Is my assumption correct? Need to sort this asap.

Thanks for all your help in advance.

Kind regards

Thomas
 

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sudden burning smell & dead battery ( clicking from the starter normally a good indicator of the battery being flat )

i am going to take a stab at the fault being the alternator has died a death on you & taken the battery out while it was at it ( hopefully not too much wiring damage in the process though )

if the AC has seized then it normally snaps the AUX belt if the AC is active so if the belt is still there & spinning happily round ( when the battery has power ) then its not the AC compressor
 

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Click4 - What will you Click4 today?
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this would be because of the AC compressor.

The air conditioning compresser has a clutch on it.. that clutch doesnt engage unless you request air conditioning.. so if the air conditioning is off theres no way for that compressor to be engaged.
 

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i had this on my mondy a couple of years ago.

i had the rattle to begin with (although it started off faint), and then the car would intermittantly cut out as i was driving along, which i didnt like at all. and in the end it just wouldnt turn over at all.

tried to get it repaired under warranty (aftermarket warranty sold with the car, not ford warranty) - long story short, the garage took the aircon pump out, turns out the (electronic) clutch on it had burned out and seized, stopping the aux belt (and therefore the engine) from turning over. the warranty company sent their aircon specialists to collect the pump and inspect it before they would pay out. in the end, they sent the pump back to the garage in pieces, saying that the reason it had overheated was because the big radiator fan at the front of the engine had stopped working, and thats what had caused it to overheat. cue much arguing with the warranty company, who when asked "how the f**k can someone make that call without having the car to inspect?", replied "i cant answer that sir, but they are the experts in this field." they wouldnt give me the details of the company for me to question them (anyone smell something a little fishy here??), so in the end i had to source a second hand pump from a breakers (£60 delivered iirc), and get the garage to fit it.

totall bill was £280 inc VAT (and aircon regas etc) from an independant Ford dealer, which wasnt too bad. since then, ive had none of the same problems. everything has worked fine, aircon works fine. but ive still got the good old rattle - aux tensioner replaced, crank pulley (or whatever its called) still to be replaced.

im pretty sure i read that if you're handy with a spanner, and have got axle stands/ramps then you can do it yourself. then it just needs regassing.

but either way, as much of a pain in the bum as it might be, its not the most expensive fix in the world!

hope that helps a bit

rich
 

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Hi Charuvil
I've got exactly the same issue. And this is not the compressor. The pulley bearing is damaged. When AC is not ON, the clutch is not engaged and the pulley should rotate freely. But it's not. You have to take off the belt to prove it. In my case the clutch with AC is easily turns but the pulley which is driven by strap wedge is obliterated. It could be because of the clutch. I believe it wasn't gripping properly and was sliding. After prolonged use the temperature have increased to the point that caused the pulley bearing damage. It's unable to turn any more.
The question is: how do I dismount this pulley?
 

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Discussion Starter · #6 ·
Rich, you hit the nail on its head! I had the exactly the same problem with the engine cutting out twice. Then the engine wouldn't turn over. Bought a new battery(I had the original motorcraft battery, about 11 years old) and still the engine wouldn't turn over. I called a recovery truck. The recovery guy just came and cut the aux belt. With no aux belt, the engine started instantly.

I got a used compressor off a breaker for £25 (delivered). Gave it to the garage who fitted the compressor along with a new belt, tensioner and regas. Now the engine idles silently at 650-700 rpm.

Happy to get my car back on road after three weeks
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Hi Mijamoto, you may follow this link towards your first step in solving this issue along with a replacement compressor:

http://www.fordwiki.co.uk/index.php?title=Auxiliary_belt_tensioner_replacement

Cheers
 
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