Engine Cooling: Other Mercury Milan I

Material

Material

Fail Safe Cooling (2.3L and 3.5L only)

The vehicle has a strategy built into the PCM that will control the engine if it starts to overheat.

Stage 1 of the strategy will commence if the engine starts to overheat. The cylinder head temperature (CHT) sensor transmits a signal to the PCM, which then moves the temperature gauge pointer into the red zone.

If the engine is not switched OFF and the temperature continues to rise, the powertrain check lamp is illuminated. This indicates to the driver that the engine is approaching critical limits and should be stopped. At this point, DTC P1285 is set in the PCM and can be retrieved using a scan tool.

Stage 2 of the strategy will commence if the lamp and temperature gauge are ignored by the driver. The PCM will start to control the engine by cutting out cylinders and restricting the rpm to below 3,000 rpm. Simultaneously, the malfunction indicator lamp (MIL) will be illuminated. This indicates that long-term engine damage can occur and vehicle emissions will be affected. At this point, DTC 1299 is set in the PCM and can be retrieved using a scan tool.

Air is then drawn into the deactivated cylinders. This helps to control the temperature of the engine internal components. The deactivated cylinders are alternated to allow even cooling of all the cylinders.

Note. If the driver is using a high percentage of throttle travel (for example, an overtaking maneuver) when the PCM starts, engine deactivation will be delayed for 10 seconds.

Note. After the cylinder deactivation operation has begun, the engine will not revert to operating on all cylinders, even if the temperature should fall, until the ignition is switched OFF and then ON again.

Note. The malfunction indicator lamp can only be extinguished by using a scan tool after the fault has been rectified and the DTC cleared.

Stage 3 of the strategy will commence if the engine temperature still continues to rise. This will result in the engine being totally disabled before major engine damage or seizure occurs. The powertrain check lamp will begin to flash, indicating to the driver that the engine will be switched OFF after 30 seconds. This allows the driver time to choose a suitable parking place.

Note. Black arrows indicate hot, white arrows indicate cold.

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Note. Black arrows indicate hot, white arrows indicate cold.

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Note. Black arrows indicate hot, white arrows indicate cold.

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Special Tools Illustration Tool Name Tool Number 73III Automotive Meter 105-R0057 or equivalent Battery/Antifreeze Tester 014-R1060 or equivalent Pressure Test Kit 014-R1072 or equivalent Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware or equivalent scan tool

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Material

Cap

1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap if necessary.
2. Fit the pressure relief cap to the Radiator/Heater Core Pressure Tester Kit using the correct adapter.
3. Slowly pump the pressure tester until the pressure gauge stops increasing and note the highest pressure reading. Release the pressure and repeat the test. Install a new pressure relief cap if the pressure is not within specification. Refer to «SPECIFICATIONS»(ref-271067-S10148537082007110800000) .

Thermostat

A new thermostat should be installed only after the following tests and checks have been carried out

1. Pinpoint Test A, B or C
2. Thermostat Visual Inspection

Filling and Bleeding with RADKITPLUS (2.3 and 3.0L only)

1. Using the special tool, install the RADKITPLUS and follow the manufacturer's instructions to fill and bleed the cooling system.

Filling and Bleeding without RADKITPLUS (2.3L and 3.0L only)

Note. Stop-leak style pellets/products must not be used as an additive in this engine cooling system. The addition of stop-leak style pellets/products can clog or damage the cooling system, resulting in degraded cooling system performance and/or failure.

2.3L

1. Remove the degas bottle cap and the bleed valve on the back of the engine water outlet.
2. Remove the degas bottle cap and the bleed valve on the upper radiator hose.
3. Fill the cooling system through the degas bottle until coolant flows from the bleed valve and the coolant is to the MAX fill line on the degas bottle.
4. Install and tighten the bleed valve cap and install the degas bottle cap.
5. Start the engine and let it idle for 10 minutes (3.0L), 30 minutes (2.3L) or until the engine reaches normal operating temperature.
6. Allow the engine to cool and repeat Step 5 if necessary.
7. Start the engine and turn the heater to the MAX position.
8. Run the engine at 2,500 rpm for 10 minutes.
9. Repeat Step 8 if necessary.
10. Check the engine coolant level in the degas bottle and fill as necessary.

Filling and Bleeding Without RADKITPLUS (3.5L only)

1. Remove the degas bottle cap and the bleed valve on the thermostat housing.
2. Fill the cooling system through the degas bottle until the coolant is to the MAX fill line.
3. Install and tighten the bleed valve cap and install the degas bottle cap.
4. Start the engine and let it idle for 10 minutes or until the engine reaches operating temperature.
5. Turn the engine off and wait one minute before carefully removing the degas bottle cap. Open the engine bleed valve 2 complete turns.
6. Start the engine and let idle for 2 minutes, or until coolant escapes from the bleed valve, then close the valve and install the degas bottle pressure cap.
7. Idle the engine until the fans turn on, indicating the thermostat is fully open.
8. Increase the engine speed to 2,500 rpm for 30 seconds.
9. Let the engine idle for 2 minutes.
10. Carefully open the engine bleed valve 2 complete turns and idle for 30 seconds, or until coolant escapes from the bleed valve, then close the valve.
11. Repeat Steps 8 through 10 an additional 5 times.
12. Turn engine off and wait one minute before carefully removing pressure cap.
13. Attach a cooling system pressure tester to the degas bottle neck and note the level of coolant in the degas bottle.
14. Apply 100 kPa (15 psi) to the cooling system.
15. If the coolant level drops by more than 15 mm (0.59 in) when 100 kPa (15 psi) is applied, then air is trapped in the cooling system. If air is present, remove the air from the cooling system by repeating Steps 8 through 11.

Thermostat Housing - 2.3L

Note. The thermostat and thermostat housing are serviced as an assembly.

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Thermostat Housing - 3.5L

Material

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Bypass Tube - 3.0L

Material

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Coolant Pump - 2.3L

Material

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Coolant Pump - 3.0L

Special Tools Illustration Tool Name Tool Number Installer, Camshaft Pulley 303-458 (T94P-6312-AH3), part of 303-S455 Installer, Power Steering Pump Pulley (Nut only) 211-185 (T91P-3A733-A) Plate, Water Pump Pulley 303-456 (T94P-6312-AH1), part of 303-S455 Protector, Water Pump Shaft 303-457 (T94P-6312-AH2), part of 303-A455 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) Spacer, Water Pump Pulley 303-459 (T94P-6312-AH4), part of 303-S455

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