Mercury Problem Reports

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White smoke coming from the exhaust could indicate that a head gasket has blown or there is a cracked cylinder head. Our technicians tell us that removal and inspection of the cylinder heads will be required to confirm a crack is present.

Valve seats (components in the cylinder head that help seal the valve) can fall out. When this happens, it causes rough running and creates noise. Replacement of the cylinder head is commonly required to fix this problem.

On higher mileage vehicles, one or more EGR orifice in the intake manifold may plug with sludge. This can cause the engine to misfire when first accelerating because too much exhaust gas is directed into the cylinders where the orifice is not plugged. Cleaning the clogged passages should correct this concern.

Our technicians tell us the spark plugs in this engine can be very difficult to remove. Ford has issued a service bulletin (08-7-6) to address this issue, which includes a recommended procedure on how to remove the plugs. Failure to follow the recommended procedure can result in the one or more spark plugs breaking off in the cylinder head.

The recommend procedure is as follows. Using this procedure will greatly reduce the chance of breaking a spark plug.

1. Break the spark plugs loose when the engine is warm.
2. Turn each plug 1/8 to 1/4 turn and soak the treads with 1/2 to 3/4 teaspoon of Motorcraft Carburetor Tune-Up Cleaner or a quality penetrating oil. Do not try to remove the plugs at this time.
3. Let the threads soak for at least 15 minutes.
4. After the soak period, tighten and loosen each spark plug, working it back and forth until the turning effort is reduced. Then, you can remove the spark plug.

There are special tools available to remove the broken spark plugs and repair shops will often charge additional labor time, over and above the quoted spark plug replacement cost, for the removal of each broken spark plug.

The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.

The battery light may illuminate on the instrument panel because the alternator wire harness connector is damaged. A new connector kit is available and should be installed to correct this concern.

The heater hose outlet may leak coolant at the back of the intake manifold. Sometimes this is misdiagnosed as a leaking intake manifold gasket because it resembles a leaking manifold.

The fuel injectors can fail and cause drivability problems. Often there is no Check Engine light and the failures can be caused by corrosion of the connector, clogging beyond the point of cleaning, and/or internal failures.

A cosmetic crack may develop on the plastic liftgate trim panel. Our technicians tell us the Ford has released a service procedure to replace the applique without damage the the liftgate glass.

The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.

The composite (plastic) intake manifold may crack near the thermostat housing and cause a coolant leak. Ford released an updated manifold that was reinforced to prevent a recurrence. No recall was issued for this problem but Ford did extend the warranty to seven years on some models from the date of purchase.

wiring harness insulation has deteriated

The exhaust manifold often warps and cracks, breaking off the studs between the cylinder head and the exhaust manifold. A ticking type noise may be noted most noticeable when the engine is cold.

O-rings in the quick connect fittings commonly allow refrigerant to leak from the AC System. The o-rings at system quick connect fittings should be replaced.

Internal heater blower motor issues can cause a ticking noise from the heater blower when the fan is on. To correct this concern, replace the heater blower motor with a revised unit.